ACS800-17LC Hardware Manual

ABB industrial drives

Hardware manualACS800-17LC Drives (55 to 5200 kW)

List of related manuals

You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative.

Drive hardware manuals Code (English)

ACS800-17LC Hardware Manual 3AUA0000065339

ACS800 IGBT Supply Control Program Firmware Manual 3AFE68315735

ACS800 Standard Control Program Firmware Manual 3AFE64527592

Option manuals and guides

ACS800-1007LC Liquid Cooling Unit User’s Manual 3AFE68621101

ACS800-607LC 3-phase Brake Units Hardware Manual 3AFE68835861

ACS800 Brake Control Program Firmware Manual 3AFE68835631

ACW 621 Braking Chopper Sections User’s Manual 3BFE64314874

ACS800 Sine Filters User’s Manual 3AFE68389178

Fieldbus Adapters, I/O Extension Modules etc.

http://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000065339&LanguageCode=en&DocumentPartId=1&Action=Launch

http://search.abb.com/library/ABBLibrary.asp?DocumentID=3AFE68315735&LanguageCode=en&DocumentPartId=1&Action=Launch





http://search.abb.com/library/ABBLibrary.asp?DocumentID=3BFE64314874&LanguageCode=en&DocumentPartId=1&Action=Launch


ACS800-17LC Drives55 to 5200 kW

Hardware Manual

3AUA0000065339 REV B ENEFFECTIVE: 2016-06-07

2016 ABB Oy. All Rights Reserved.

5

Table of contents

Table of contents

Safety instructions

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Fiber optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Use of the hand-operated winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Work on the liquid cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Introduction to the manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Quick installation and start-up flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Hardware description

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Example circuit diagram (frames R7i+R7i and R8i+R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Example circuit diagram (frame 2×R8i+2×R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Block diagram of the main circuit with options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30General information on drive cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Cabinet layout (frames R7i+R7i and R8i+R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Swing-out frame layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Auxiliary control cubicle layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Main switch disconnecter cubicle layout (frames 2×R8i+2×R8i and up) . . . . . . . . . . . . . . . . . . . . . 35

600 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351000 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table of contents

6

Layout of LCL filter and supply module cubicles (frame 2×R8i and up) . . . . . . . . . . . . . . . . . . . . . .36Swing-out frame layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Layout of inverter module cubicle (frame 2×R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Layout of inverter module cubicle (frame 3×R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Layout of inverter module cubicles (frames 4×R8i to 9×R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Swing-out frame layout of the inverter module cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Overview of supply and inverter modules (R7i and R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Control of the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Main switch-disconnector Q1 (frames R7i+R7i and R8i+R8i) . . . . . . . . . . . . . . . . . . . . . . . . .43Supply transformer disconnecting push button (+Q959) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Operating switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Auxiliary power switch Q100 (frame sizes 2×R8i and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Grounding switch Q9 (option +F259) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Emergency stop push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Connections and use of the I/O in the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Connections to standard I/O terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Control of the inverter unit and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Connections and use of the I/O in the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Drive label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Supply, inverter and brake module label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Type code of the basic configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Mechanical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Moving the unit by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Moving the unit by fork-lift or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Moving the unit on rollers (not allowed with marine cabinets) . . . . . . . . . . . . . . . . . . . . . . . . .57Laying the unit on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Placing the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58Overview of the installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Fastening the cabinet to the floor and wall (non-marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Alternative 1 – Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Alternative 2 – Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Fastening the unit to the floor and wall (marine units, option +C121) . . . . . . . . . . . . . . . . . . . . . . .62Joining the shipping splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Preparing the liquid pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Fastening the cabinets together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Connecting the liquid pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Table of contents

7

Connecting the PE busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Connecting the DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Planning the electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Selecting the supply disconnecting device (disconnecting means) . . . . . . . . . . . . . . . . . . . . . . . . . 69Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Requirements for motor insulation and bearings and drive filters . . . . . . . . . . . . . . . . . . . . . 71

Explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72High-output motors and IP 23 motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73HXR and AMA motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73ABB motors of types other than M2_, M3_, HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . 73When DC link voltage is increased with parameter settings . . . . . . . . . . . . . . . . . . . . . 73Calculating the rise time and the peak line-to-line voltage . . . . . . . . . . . . . . . . . . . . . . 73Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Coaxial cable (for use with Advant Controllers AC 80/AC 800) . . . . . . . . . . . . . . . . . . . . . . . 80

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Protecting the drive, input power cable, motor and motor cable in short circuit situation and against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Protecting the drive and input power cable in short-circuit situations . . . . . . . . . . . . . . . . . . 81Protecting the motor and motor cable in short-circuit situations . . . . . . . . . . . . . . . . . . . . . . 82Protecting the drive, motor cable and input power cable against thermal overload . . . . . . . . 82Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Insulation requirements for the motor temperature sensor circuit . . . . . . . . . . . . . . . . 83Protecting the drive against ground faults in the drive, motor or motor cable . . . . . . . . . . . . . . . . . 83Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Implementing the Prevention of unexpected start function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Implementing the power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Supplying power for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Terminals for connecting external control voltage (option +G307) . . . . . . . . . . . . . . . . . . . . 86Units without optional auxiliary control transformer and without terminals for connecting external

Table of contents

8

control voltage (option +G307) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86Implementing a safety switch between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87Using a contactor between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88Switching the motor power supply from drive to direct-on-line . . . . . . . . . . . . . . . . . . .88Switching the motor power supply from direct-on-line to drive . . . . . . . . . . . . . . . . . . .89

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89Considering the PELV on installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . .90

Electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Braking resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Checking the compatibility with IT (ungrounded) and corner grounded TN systems . . . . . . . . . . . .92Connecting the input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Connecting the motor cable – units with no common motor terminals cubicle option +H359 . . . . .94Connection diagram – single inverter module feeds one motor . . . . . . . . . . . . . . . . . . . . . . .94Connection diagram – parallel inverter modules feed one motor . . . . . . . . . . . . . . . . . . . . . .95Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Connecting the motor cable (units with the common motor cable connection terminals cubicle option +H359) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Connecting external power supply for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100Frames R7i×R7i and R8i×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100Frames 2×R8i and up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Standard unit without optional auxiliary control voltage transformer or terminals for con-necting external control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101Units with optional auxiliary control voltage transformer and without terminals for connect-ing external control voltage (+G307) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101Units with terminals for connecting external control voltage (option +G307) and without op-tional auxiliary control voltage transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Connecting the control cables for the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102Connecting the control cables for the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107Cabling of pulse encoder interface module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107Fiber optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Table of contents

9

Installation checklist

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Start-up

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Connecting voltage to the input terminals and auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . 112Closing the main contactor/breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Checking the setting of the ground fault monitoring device . . . . . . . . . . . . . . . . . . . . . . . . . 112Supply unit control program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Inverter unit control program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Liquid cooling unit control program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Switching the control panel between the supply and inverter units . . . . . . . . . . . . . . . . . . . . . . . . 114ACS800-17LC-specific parameters in the IGBT Supply Control Program . . . . . . . . . . . . . . . . . . 115

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Default values of parameters with the ACS800-17LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

ACS800-17LC-specific parameters in the application program . . . . . . . . . . . . . . . . . . . . . . . . . . 117Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Actual signals and parameters of supply unit in inverter unit program . . . . . . . . . . . . . . . . 117

Fault tracing

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Warning/Fault message from the unit not being monitored by the control panel . . . . . . . . . 119Conflicting ID numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Maintenance

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Replacing the cooling fan of converter module (frames R7i and R8i) . . . . . . . . . . . . . . . . . 121Replacing the additional fan in the incoming cubicle (frames R7i+R7i and R8i+R8i) . . . . . 122Replacing the auxiliary control cubicle fan (frames 2×R8i+2×R8i and up) . . . . . . . . . . . . . 123Replacing the fan in the incoming cubicle (frames 2×R8i+2×R8i and up) . . . . . . . . . . . . . . 124Replacing the cooling fans in supply module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125Replacing the inverter module fans (2×R8i and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Replacing the additional fan in the common motor terminals cubicle . . . . . . . . . . . . . . . . . 126

Reduced run capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Replacing supply and inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Installing the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132Installing the installation stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Table of contents

10

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134Replacing the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

Replacing the PPCS branching unit (APBU-xx) memory backup battery . . . . . . . . . . . . . . . . . . .135

Internal cooling circuit

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137Internal cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137Connection to a cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Connection to an ACS800-1007LC cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138Connection to a custom cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138Coolant temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Filling up and bleeding the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139Drive line-ups with an ACS800-1007LC cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139Drive line-ups with a custom cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Draining the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140Adding inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Temperature limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141Pressure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142Freeze protection and corrosion inhibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Glycol concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Technical data

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

Type equivalence table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1471-phase brake choppers (option +D150) and resistors (option +D151) . . . . . . . . . . . . . . . . . . . . .1483-phase brake units (option +D152) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

Main circuit AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150Main circuit DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153Internal cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154Terminal and lead-through data for the input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155Terminal and lead-through data for the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

Units without common motor terminal cubicle (no option +H359) . . . . . . . . . . . . . . . . . . . . .156Units with the Common Motor Terminal (CMT) cubicle (option +H359) . . . . . . . . . . . . . . .157

Table of contents

11

Terminal and lead-through data for the resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Terminal and lead-through data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Brake resistor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Control unit (RDCU/RMIO) connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16024 V DC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160Isolation and grounding diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Compliance with EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Dimensions

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Table of dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Frame sizes R7i+R7i and R8i+R8i (bottom entry/exit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173Frame sizes R7i+R7i and R8i+R8i (marine units, +C121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Providing feedback on ABB manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Table of contents

12

Table of contents

13

Safety instructions

What this chapter contains

This chapter contains safety instructions you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, motor or driven equipment. Read the safety instructions before you work on the unit.

Use of warnings

Warnings caution you about conditions which can result in serious injury or death and/or damage to the equipment, and advise on how to avoid the danger. The following warning symbols are used in this manual:

Electricity warning warns of hazards from electricity which can cause physical injury and/or damage to the equipment.

General warning warns about conditions, other than those caused by electricity which can result in physical injury and/or damage to the equipment.

Electrostatic sensitive devices warning warns of electrostatic discharge which can damage the equipment.

Safety instructions

14

Safety in installation and maintenance

Electrical safety

These warnings are intended for all who work on the drive, motor cable or motor.

WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:

• Only qualified electricians are allowed to install and maintain the drive.

• Before working on the drive, isolate the whole drive from the supply. The main switch on the cabinet door does not remove the voltage from the input busbars of the drive.

• Never work on the drive, motor cable or motor when main power is applied. After switching off the input power, always wait for 5 min to let the intermediate circuit capacitors discharge before you start working on the drive, motor or motor cable. Measure the voltage between + and - DC busbars with a multimeter (impedance at least 1 Mohm) to ensure that the drive is discharged before beginning work.

• Apply temporary grounding before working on the unit.

• Do not work on the control cables when power is applied to the drive or to the external control circuits. Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off.

• Do not make any insulation or voltage withstand tests on the drive or drive modules.

• When reconnecting the motor cable, always check that the phase order is correct.

• When joining shipping splits (if any), check the cable connections at the joints before switching on the supply voltage.

• Live parts on the inside of the doors are protected against direct contact. Pay special attention when handling metallic shrouds.

Note:

• The motor cable terminals on the drive are at a dangerously high voltage when the input power is on, regardless of whether the motor is running or not.

• The drive DC bus and brake resistor terminals (R+, R-, R1.1, R1.2, R1.3, R2.1, R2.2. and R2.3) carry dangerous voltage (over 500 V).

• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the relay outputs of the drive system.

• The Prevention of unexpected start function (option +Q950) and the Safe torque off function (option +Q968) do not remove the voltage from the main and auxiliary circuits.

• At installation sites above 2000 m (6562 ft), the terminals of the RMIO board and optional modules attached to the board do not fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 61800-5-1.

Safety instructions

15

Grounding

These instructions are intended for all who are responsible for the grounding of the drive.

WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction:

• Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and interference.

• Make sure that grounding conductors are adequately sized as required by safety regulations.

• In a multiple-drive installation, connect each drive separately to protective earth (PE).

• Do not install a drive equipped with optional EMC filter +E202 to an ungrounded power system or a high resistance-grounded (over 30 ohms) power system.

Note:

• Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations.

• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA DC, a fixed protective earth connection is required by EN 61800-5-1, 4.3.5.5.2. See also Selecting the power cables, page 74.

Safety instructions

16

Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives.

WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction:

• Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.

Before installation and maintenance work on the drive:

• Stop the motor.

• Ensure that there is no voltage on the drive power terminals according to step 1 or 2, or if possible, according to the both steps.

1. Disconnect the motor from the drive with a safety switch or by other means. Measure that there is no voltage present on the drive input or output terminals (L1, L2, L3, U1, V1, W1, U2, V2, W2, R+, R-).

2. Ensure that the motor cannot rotate during work. Make sure that no other system, like hydraulic crawling drives, is able to rotate the motor directly or through any mechanical connection like felt, nip, rope, etc. Measure that there is no voltage present on the drive input or output terminals (L1, L2, L3, U1, V1, W1, U2, V2, W2, R+, R-, R1.1, R1.2, R1.3, R2.1, R2.2. and R2.3). Ground the drive output terminals temporarily by connecting them together as well as to the PE.

Safety instructions

17

General safety

These instructions are intended for all who install and service the drive.

WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:

• Cover the drive when installing to ensure that dust from borings and grindings or foreign objects do not enter the drive. Electrically conductive dust inside the unit may cause damage or lead to malfunction.

• Ensure sufficient cooling of the unit.

• Use extreme caution when manoeuvring heavy inverter, supply and filter modules.

• Beware of hot surfaces. Some parts inside the drive cabinet, such as heatsinks of power semiconductors, remain hot for a while after the disconnection of the electrical supply.

• Pay attention to rotating cooling fans. The cooling fans may continue to rotate for a while after the disconnection of the electrical supply.

• Recommendation: Do not fasten the cabinet by riveting or welding. However, if electric welding is the only way to mount the cabinet, follow the instructions given in chapter Mechanical installation. Ensure that welding fumes are not inhaled. If the welding return wire is connected improperly, the welding circuit may damage electronic circuits in the cabinet.

Printed circuit boards

Fiber optic cables

WARNING! Ignoring the following instructions can cause damage to the printed circuit boards:

• The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily.

WARNING! Ignoring the following instructions can cause equipment malfunction and damage to the fiber optic cables:

• Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. The minimum allowed bend radius is 35 mm (1.4 in.).

Safety instructions

18

Use of the hand-operated winch

These instructions are intended for all who use the hand-operated winch delivered with the drive when replacing the supply or inverter modules.

WARNING! Ignoring these instructions can cause physical injury or death, or damage the to equipment.

• Before using the winch for the first time, spool out 2 meters (6 feet) of cable, then rewind the cable onto the drum keeping enough tension on the cable to make sure no slack is left on the drum.

• When lowering the module, keep in mind that any slack on the winch may cause the module to suddenly drop for several centimetres.

• After using the winch, rewind the cable onto the drum keeping enough tension on the cable to make sure no slack is left on the drum.

Work on the liquid cooling system

These instructions are intended for all who are responsible for installation and maintenance work of the liquid cooling system of the drive.

WARNING! Ignoring the following instructions can cause physical injury or damage to the equipment:

• Beware of hot liquid. Do not work on the liquid cooling system until the pressure is lowered down by stopping the pumps. High-pressure warm coolant (6 bar, max. 50°C) is present in the internal cooling circuit when it is in operation.

• Before power switch-on, make sure that the internal cooling circuit is filled up with coolant. Running the pump dry will damage it. Also the drive will not cool down.

• Units with a liquid cooling unit option (+C199, +C140, +C141): Do not open the pump inlet or outlet valves before filling up the internal cooling circuit. The pumps are prefilled with a water-glycol-inhibitor mixture to prevent corrosion and the valves are closed at the factory.

• Avoid skin contact with coolant, especially antifreeze. Do not syphon them by mouth. If such substance is swallowed or gets into the eyes, seek medical advice.

• Do not overtighten the outer union of the nuts of the liquid hoses - leave 2 to 3 mm of thread visible. Overtightening will break the hose.

• Drain the unit before storing in temperatures below 0°C. Freezing of the liquid cooling system is not allowed. If the ambient temperature is below +5°C, add antifreeze and corrosion inhibitors to the cooling liquid. Operation at temperatures below zero is not permitted, not even with antifreeze.

2 mm

Safety instructions

19

Safe start-up and operation

General safety

These warnings are intended for all who plan the operation of the drive or operate the drive.

WARNING! Ignoring the following instructions can cause physical injury or death or damage the equipment:

• Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line.

• Do not activate automatic fault reset functions of the drive control program if dangerous situations can occur. When activated, these functions will reset the drive and resume operation after a fault.

• Do not control the motor with the disconnecting device (means); instead, use the control panel keys and , or commands via the I/O board of the drive. The maximum allowed number of charging cycles of the DC capacitors ie, power-ups by applying power, is five in ten minutes.

• Do not use the Prevention of unexpected start function or Safe torque off function for stopping the drive when the inverter unit(s) is running. Give a Stop command instead.

Note:

• If an external source for start command is selected and it is ON, the drive (with Standard Control Program) will start immediately after fault reset unless the drive is configured for 3-wire (a pulse) start/stop.

• When the control location is not set to Local (L not shown in the status row of the display), the stop key on the control panel will not stop the drive. To stop the drive using the control panel, press the LOC/REM key and then the stop key .

Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives.

WARNING! Do not run the motor above the rated speed. Motor overspeed leads to overvoltage which may result in explosion of the capacitors in the intermediate circuit of the drive.

Safety instructions

20

Safety instructions

21



This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.

Applicability

This manual applies to the hardware of the ACS800-17LC drives. For the firmwares and optional devices, see the appropriate manuals.

Target audience

This manual is intended for people who plan the installation, install, commission, use and service the drive. Read the manual before working on the drive. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

The manual is written for readers worldwide. Both SI and imperial units are shown.

Contents

The chapters of this manual are briefly described below.

Safety instructions gives safety instructions for the installation, commissioning, operation and maintenance of the drive.

Introduction to the manual introduces the manual.

Hardware description describes the operation principle and construction of the drive.

Mechanical installation instructs how to move, place and mount the drive.

Planning the electrical installation provides advice on motor and cable selection, the protective functions of the drive, and cable sizes and routing.

Electrical installation instructs the electrical of the drive.

Installation checklist helps in checking the mechanical and electrical installation of the drive.

Maintenance contains preventive maintenance instructions.

Fault tracing contains troubleshooting instructions.


22

Technical data contains the technical specifications of the drive eg, ratings, frame sizes and technical requirements and provisions for fulfilling the requirements for CE and other markings.

Dimensions contains information on the dimensions of the drive.

Related documents

See the List of related manuals on the inside of the front cover.

Categorization by frame size and option code

The instructions, technical data and dimensional drawings which concern only certain drive frame sizes are marked with the symbol of the frame size (such as “2×R8i+2×R8i”, etc.). The frame size is not marked on the drive designation label. To identify the frame size of your drive, see section Type equivalence table on page 147.

The instructions and technical data which concern only certain optional selections are marked with option codes eg, +E202.

The options included in the drive can be identified from the option codes visible on the type designation label. The option selections are listed in section Type designation key on page 50.

Quick installation and start-up flowchart

Task See

Plan the installation.

Check the ambient conditions, ratings, required external cooling arrangements, input power connection, compatibility of the motor, motor connection, and other technical data.

Select the cables.

Technical data, page 145

Planning the electrical installation, page 69

Option manuals (if optional equipment is included)

Unpack and check the units.

Check the type code indicated by the type designation label with the original order. If the drive is about to be connected to an IT (ungrounded) system, check that the drive is not equipped with EMC filtering +E202. Check that all necessary optional modules and equipment are present and correct.

Mechanical installation, page 55

Hardware description, page 27

For instructions on how to disconnect the EMC filtering, contact your local ABB representative.

If the drive has been non-operational for more than one year, the drive DC link capacitors need to be reformed. Contact your local ABB representative for more information.

Only intact units may be started up.

Check the installation site. Checking the installation site, page 55


23

Terms and abbreviations

Route the cables. Routing the cables, page 80

Mount the cabinet line-up. Mechanical installation, page 55

Check the insulation of the motor and the motor cable.

Checking the insulation of the assembly, page 91

Connect the power cables. Connect the control and the auxiliary control cables.

Electrical installation, page 91

Check the installation. Installation checklist, page 109

Start up the drive. Start-up, page 111 and appropriate firmware manual

Term/Abbreviation Explanation

AGPS Gate driver power supply board. An optional board within drives, used to implement the Prevention of unexpected start function.

APBU Optical branching unit for fiber links that use the PPCS protocol. The unit is used for connecting parallel-connected supply and inverter modules to the RDCU.

ASTO Safe torque off board. An optional board used to implement the Safe torque off function.

Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary. The chopper operates when the DC link voltage exceeds certain maximum limit. The voltage rise is typically caused by deceleration (braking) of a high inertia motor.

Brake module Brake chopper enclosed inside a metal enclosure. See Brake chopper.

Brake resistor Dissipates the drive surplus braking energy conducted by the brake chopper to heat. Essential part of the brake circuit. See Brake chopper.

CMF Common mode filtering

Common motor terminal cubicle

Cubicle with the busbars for the motor cable connection

DDCS Distributed drives communication system; a protocol used in optical fiber communication inside and between ABB drives.

EMC Electromagnetic compatibility

Task See


24

Four-quadrant operation

Operation of a machine as a motor or generator in quadrants I, II, III and IV as shown below. Also used as an attribute of a drive; a regenerative drive can operate the electric machine in all four quadrants, a non-regenerative only in two. In quadrants I and III, the machine operates as a motor, whereas in quadrants II and IV it operates as a generator (regenerative braking).

Frame (size) Refers to power modules that share a similar mechanical construction, for example:

• inverter modules of frame R8i

• frame 2×R8i + 2×R8i includes two size R8i supply modules and two R8i inverter modules.

To determine the frame size of a component, refer to section Type equivalence table on page 147..

IGBT Insulated gate bipolar transistor

IGBT supply module Bidirectional IGBT bridge and related components enclosed inside a metal enclosure. Used as the supply module in regenerative and low-harmonic drives.

IGBT supply unit (ISU) IGBT supply modules under control of one control board, and related components. See IGBT supply module.

Inverter Converts direct current and voltage to alternating current and voltage.

Inverter module Inverter bridge, related components and drive DC link capacitors enclosed inside a metal enclosure.

Inverter unit (INU) Inverter module(s) under control of one control board, and related components. One inverter unit typically controls one motor. See Inverter module.

LCL filter Inductor-capacitor-inductor filter for attenuating harmonics

PPCS Power plate communication system; a protocol used in the optical fiber link that controls the output semiconductors of a power module.

RAPI Auxiliary power interface board.

RDCU Drive control unit. The RDCU is a separate unit consisting of an RMIO board built in a plastic housing.

RFI filter Radio-Frequency Interference filter.


Speed

Torque

I

IVIII

II


25

RMIO Motor control and I/O board. The RMIO is a versatile control board and an IO interface the use of which is determined by the control program loaded onto the board. The RMIO is widely used in the ACS800 product series, eg. for controlling drive modules, inverter units, supply units, cooling units, brake units, etc. See also RDCU.

STO Safe torque off function

THD Total harmonic distortion



26


27



This chapter describes the operation principle and the construction of the drive in short.

Product overview

The ACS800-17LC is a four-quadrant, cabinet-installed liquid-cooled drive for controlling asynchronous AC induction motors and generators, and permanent magnet synchronous motors and generators.


28

Single-line circuit diagram of the drive

Example circuit diagram (frames R7i+R7i and R8i+R8i)

This diagram represents frame R7i+R7i and R8i+R8i drives without any EMC, du/dt filter or brake options.

The supply unit and inverter unit have their own control boards (RDCU control units) and control programs.

M

Ground fault monitoring (+Q954)

230 V AC or 115 V AC (+G304)

DC bus

M

3~

230/115 V AC

M

230/115 V AC

Charging circuit

Supply unit Inverter unit

Main contactor

LCL filter

Main switch disconnector

Main supply


29

Example circuit diagram (frame 2×R8i+2×R8i)

This diagram represents a frame 2×R8i+2×R8i drive without any EMC, du/dt filter or brake options. Both the supply unit and the inverter unit consist of two parallel frame R8i converter modules.

The supply unit and inverter unit have their own control boards (RDCU control units) and control programs.

M

Ground fault monitoring (+Q954)

230 V AC or 115 V AC (+G304)

M

DC bus

M

3~

230/115 V AC230/115 V AC

Mainsupply

M M

230/115 V AC230/115 V AC

Charging circuit

Supply unit Inverter unit

Main breaker

LCL filter


30

Block diagram of the main circuit with options

L1

L2

L3

U2

V2

W2

5)

6)

2)

R1.1 R2.1 R3.1 R1.2 R2.2 R3.2

7) 1)

No. Description

1 Main switch and disconnector and charging circuit

Drives of frame sizes R7i+R7i and R8i+R8i are equipped with a main switch disconnector and contactor:

Drives of frame sizes n×R8i+n×R8i are equipped with an air circuit breaker:

2 Optional EMC filter (+E202)

3 LCL filter

4 Supply module

5 Brake chopper (option +D150)

6 Brake resistors (option +D151)

7 3-phase brake chopper (option +D152)

8 Inverter module. The module is equipped with du/dt as standard. For frame R7i, the filter is optional (+E205)

9 Sine filter (option +E206)

RMIOU<

3) 4) 8) 9)


31

General information on drive cabinet layout

The drive consists of cubicles that contain the supply, motor and auxiliary control connection terminals, 1 to 10 IGBT supply module(s) forming the supply unit, 1 to 9 inverter modules forming the inverter unit, and optional equipment. The actual arrangement of the cubicles varies from type to type and the selected options.

An example line-up is shown below: ACS800-17LC-1240-7+C141+D152.

A Auxiliary control cubicle (optional)

B Incoming cubicle

C LCL filter cubicle

D Supply module cubicle

E Inverter module cubicle

F Brake chopper cubicle (option +D152)

G Liquid cooling unit (option +C141)

A B C D E F G


32

Cabinet layout (frames R7i+R7i and R8i+R8i)

No. Description

A Incoming cubicle

B LCL filter cubicle

C Supply and inverter module cubicle

1 Drive control panel

2 Operating switch

3 Meters (optional)

4 Main switch handle

5 PE terminal (cabinet grounding busbar at the side of the cabinet)

6 Auxiliary voltage transformer (T10)

7 Input power cable connection terminals

8 Main switch

9 Input fuses

10 Cabinet fan

11 LCL filter

12 IGBT supply module (behind the swing-out frame)

13 Inverter module (behind the swing-out frame)

14 Swing-out frame with supply and inverter unit control electronics, I/O terminal blocks and communication options. See Swing-out frame layout on page 33.

15 Cooling fans

16 Motor cable connection terminals (busbars behind the fan)

17 Motor grounding terminal (common cabinet grounding busbar behind the coolant pipe)

Doors closed

Doors open

1

8

7

5

4

A B C

2

3

1210

11

6

13

16

15

15

17

14

9


33

Swing-out frame layout

No. Description

1 Terminal block of the inverter (option +L504). Hardwired to terminals of the inverter control board.

2 Inverter control unit (RDCU) including the control board (RMIO)

3 Supply control unit (RDCU) including the control board (RMIO)

4 I/O module adapter (AIMA, optional)

5 24 V DC power supply

6 24 V DC back-up accumulator (auxiliary power interface board [RAPI])

7 Relay for disconnecting the power supply for the cooling fans and connecting the heating on when the drive is powered but not running.

8 Pt100 relays for motor temperature supervision (option +L506)

9 Internal control relays

1 3

4

5

6

9 7

2

8


34

Auxiliary control cubicle layout

An optional 400 mm or 600 mm wide auxiliary control cubicle is available in frames 2×R8i and up. Some options, such as auxiliary voltage transformer, require an auxiliary control cubicle. A 600 mm wide cubicle is shown below.

No. Description

1 Handle of main switch for auxiliary circuits

2 Main switch for auxiliary circuits

3 Space for control relays, devices, etc.

4 Air to liquid heat exchanger

5 Cooling fan

6 Auxiliary voltage transformer (T10)

Door closed Door open

6

3

4

5

2

1


35

Main switch disconnecter cubicle layout (frames 2×R8i+2×R8i and up)

600 mm wide cubicle

1000 mm wide cubicle

Door closed Door open

600 mm wide cubicle

No. Description

1 Operating switch of the supply unit (Off/On/Start)

2 Emergency stop reset push button (option +G331)

3 Handle of grounding switch (option +F259)

4 Meters (options +G335, +3G335, +G334)

5 Main switch disconnector (air circuit breaker)

6 Charging circuit switch and handle

7 Busbars for input power cables

8 PE main busbar of the cabinet (behind the cooling liquid pipe)

9 Heat exchanger and fans

10 Grounding switch (option +F259)

4

6

5

9

10

8

7

312

Doors closed Doors open

4

3

6

5

10

8

7

9

3

21


36

Layout of LCL filter and supply module cubicles (frame 2×R8i and up)

An example layout of the LCL and supply module cubicles of frame 2×R8i is shown below. The larger units employ similar cubicles in parallel.

No. Description

A LCL filter cubicle

B Supply module cubicle

1 AC fuses

2 LCL filter components (2×L, 1×C)

3 DC fuses

4 Supply modules (behind the swing-out frame)

5 Swing-out frame for the supply unit control electronics

6 Fans

Doors closed Doors open

1

4

6

3

25

A B


37

Swing-out frame layout

The swing-out frame inside the supply module cubicle provides space for the control unit (RDCU), branching unit (APBU), I/O signal and auxiliary circuit terminal blocks, breakers and relays.

The frame can be opened by removing the mounting screws and moving the swing-out frame aside. Depending on selected options, the actual equipment may differ from what is depicted below.

No. Description

1 Auxiliary voltage distribution terminal block


3 24 V DC back-up accumulator (auxiliary power interface board [RAPI])

4 Supply module control unit (RDCU) including the control board (RMIO)

5 Circuit breakers for auxiliary circuits

6 Ground fault monitoring relay (option +Q954)

7 Internal control relays

8 APBU Branching Unit with parallel supply modules

3

4

5 6

8

1

27


38

Layout of inverter module cubicle (frame 2×R8i)

2×R8i inverter units are installed in a cubicle as shown below.

No. Description

1 Inverter unit control panel

2 Inverter unit LED panel (optional)

3 Handle with marine construction (option +C121)

4 DC fuses

5 Inverter modules (behind the swing-out frame)

6 Swing-out frame with inverter unit control electronics, I/O terminal blocks and communication options

7 Motor cable terminals (busbies behind the fans)

8 Terminal block for connection of prevention of unexpected start circuit (option +Q950)

9 Terminal block for connection of motor temperature supervision (option +L505 or +L506)

10 Fan

11 Motor grounding terminal (common cabinet grounding busby behind the coolant pipe)

2×R8i, door closed

12

3

2×R8i, door open

4

5

6

7

11

8 91010


39

Layout of inverter module cubicle (frame 3×R8i)

3×R8i inverter units are installed in a 700 mm wide cubicle as shown below.

No. Description

1 Inverter unit control panel

2 Inverter unit LED panel (optional)

3 Handle with marine construction (option +C121)

4 DC fuses

5 Inverter modules (behind the swing-out frame)

6 Swing-out frame with inverter unit control electronics, I/O terminal blocks and communication options

7 Motor cable terminals (busbies behind the fans)

8 Terminal block for connection of prevention of unexpected start circuit (option +Q950)

9 Motor grounding terminal (common cabinet grounding busby behind the coolant pipe)

10 Fans

11 Terminal block for connection of motor temperature supervision (option +L505 or +L506)

3×R8i, door closed

12

3

9

3×R8i, door open

4

5

6

7

11

8 10


40

Layout of inverter module cubicles (frames 4×R8i to 9×R8i)

Inverter units of frames 4×R8i to 9×R8i are composed of parallel-connected 2×R8i and 3×R8i cubicles.

Swing-out frame layout of the inverter module cubicles

The swing-out frame inside the inverter module cubicle provides space for the control unit (RDCU), branching unit (APBU), I/O signal and auxiliary circuit terminal blocks, breakers and relays.

The frame can be opened by removing the mounting screws and moving the swing-out frame aside. Depending on selected options, the actual equipment may differ from what is depicted below.

No. Description

1 Inverter control unit (RDCU) including the control board (RMIO)

2 RDCO DDCS Adapter Module (options +L508 and +L509)

3 APBU Branching Unit with parallel-connected inverter modules


5 24 V DC back-up accumulator (Auxiliary Power Interface Board [RAPI])

6 Terminal block for external IO connections, hard wired to RDCU terminals (option +L504)

7 Terminal blocks for auxiliary voltage distribution

8 Auxiliary circuit breakers

9 Relays for motor temperature supervision (options +L505 and +L506)

10 AIMA I/O Module Adapter (optional)

3

4

5

6

8

9

10

7

1

2


41

Overview of supply and inverter modules (R7i and R8i)

The figure below shows the supply/inverter module of size R7i and R8i. The control unit containing the RMIO board is external and located in the swing-out frame of the module cubicle. The control unit is connected to the inverter module(s) by a fiber optic link, distributed through an optical branching unit. In the inverter modules, the optic link connects to the AINT board, the terminals of which are accessible through a hole on the front panel of the module.

1 AC busbars/knives (U2,V2,W2). Fit into quick connector on the rear assembly plate of the cabinet.

2 DC busbars (+, -)

3 Fiber optic connectors. V1, V2: control board (RMIO) connection. Other fiber optic connectors are not in use in supply units.

4 Coolant in connection

5 Coolant out connection

6 Handle

7 Air/liquid heat exchanger

8 Terminal block X17 (not in use in supply modules)

1

2

3

4

5

7

6

8


42

Overview of power and control connections

The following diagram shows the power connections, control interfaces and I/O options of the drive.

Ext

ern

al c

on

tro

l via

an

alo

g/d

igita

l in

puts

and

ou

tpu

ts,

see

pag

e 1

03.

Inp

ut

pow

er

Co

ntr

ol b

oa

rd

(RM

IO)

Co

ntr

ol u

nit

(RD

CU

)

Pa

ram

ete

r se

ttin

g a

nd

dia

gno

stic

s th

rou

gh

C

DP

31

2R C

ont

rol P

ane

l (a

nd

rela

ted

acc

esso

ries)

.

No

te:

By

defa

ult,

the

co

ntro

l pan

el o

f th

e d

rive

is s

et

to c

ontr

ol t

he

inve

rte

r u

nit.

Co

ntr

ol b

oa

rd

(RM

IO)

Co

ntr

ol u

nit

(RD

CU

)

Op

tio

na

l mo

du

le 1

: I/O

ex

tens

ion

(RA

IO,

RD

IO),

pu

lse

enco

der

inte

rfa

ce

(RTA

C),

or

field

bus

ada

pter

(R

MB

A,

RD

NA

, R

PB

A e

tc.)

Op

tio

na

l mo

du

le 2

: I/O

ex

tens

ion

(RA

IO,

RD

IO)

or

puls

e en

cod

er in

terf

ace

(R

TAC

)

Op

tio

na

l mo

du

le 3

: DD

CS

co

mm

unic

atio

n o

ptio

n

(RD

CO

-01,

RD

CO

-02

or

RD

CO

-03)

fiber

op

tic li

nk

RD

CO

CH

0R

DC

OC

H1

Sup

ply

uni

t con

tro

l circ

uitr

y in

clu

din

g d

oor

sw

itch

es,

ch

arg

ing

cir

cuit

con

tro

l, m

ain

co

nta

cto

r co

ntr

ol,

etc

.

01

RE

SE

TG

EMER

EN

CY

OS

TP

S

M 3 ~

L1 L2 L3

U2

V2

W2


43

Control of the supply unit

As standard, the user controls the supply unit solely by the operating switches on the cabinet door (start/stop). The door switches are connected to the I/O interface of the supply unit at the factory. The wiring may not be changed by the user. In most cases, the user does not need any other means to control the supply unit. However, it is also possible to control the supply unit with the control panel or through a fieldbus. The use of the panel is possible when the panel is not needed for the control of the inverter, for example during a start-up or testing of the supply unit. The fieldbus control is possible when the control unit of the supply unit has been equipped with an optional fieldbus adapter module.

For more information on the control through the fieldbus, see the appropriate firmware manual.

Main switch-disconnector Q1 (frames R7i+R7i and R8i+R8i)

The switch-disconnector handle switches the main and auxiliary voltages to the drive on and off.

Supply transformer disconnecting push button (+Q959)

The red push button disconnects the control voltage from the supply transformer breaker. The push button is added on the cabinet door at the factory by ABB. The installer of the drive must wire the button to the breaker control circuit on the installation site.

Operating switch

Auxiliary power switch Q100 (frame sizes 2×R8i and up)

The auxiliary power switch controls all auxiliary voltages in the cabinet including the DC link charging circuit. The auxiliary power switch must be closed before the drive can be started.

Grounding switch Q9 (option +F259)

When closed, the optional grounding switch connects the supply phases L1, L2 and L3 to PE. The switch is interlocked with the main contactor/breaker control circuit:

0 Stops the supply unit and the drive, opens the main contactor/breaker and stops the cooling fans.

1 Keeps the main contactor/breaker closed and the supply unit in operation (on command. Normal operation.

S Charges the intermediate DC circuit before closing the main contactor/breaker and starts the cooling fans.

01

S


44

The switch cannot be closed if the contactor/breaker is closed. The main contactor/breaker cannot be closed before the grounding switch has been opened.

Emergency stop push button

An emergency stop button is included with options +Q951 and +Q952.

Reset button

A reset button is included with options +Q951 and +Q952. The button resets an emergency stop, after which the supply unit can be started using the operating switch.

Note: Drive faults are reset via the drive control panel or serial communication.

G

E

MER ENCY

OS T P

RESET


45

Connections and use of the I/O in the supply unit

The table and the figure below describe the connections and use of the I/O in the supply unit. The use of I/O is fixed in the supply unit control program and the wiring to RMIO terminals are made accordingly at the factory. The settings of the supply control program and the connections of the supply unit I/O must not be changed by the user.

IO Name Use in the control program Connected device / Purpose

RDCU standard I/O channel

AI1 Not in use Not in use as default. Not in use as default.

A12 Not in use Not in use as default. Not in use as default.

AI3 Not in use Not in use as default. Not in use as default.

DI1 ALARM / FAULT Overtemperature supervision: 1->0: Alarm.

0: Fault (after preset time delay).

LCL filter temperature sensors (in series)

DI2 ON / OFF Supply module on/off control. 0->1: On.

0: Off.

Operating switch, control circuitry

DI3 ACK MAIN CONTACTOR

Main breaker/contactor supervision. 1: closed (enables supply unit start)

Contact in main breaker/contactor control circuit

DI4 EARTH FAULT Ground fault supervision. Can be activated or inactivated by parameter. 1: No fault. Not in use as default.

Insulation monitoring device (option +Q954)

DI5 ALARM / FAULT Supervision of cooling unit. Can be activated or inactivated by parameter. 1->0: Alarm. 0: Fault (after preset time delay). Not in use as default.

Cooling unit monitoring circuit. Not in use but hard-wired to +24 V DC of RDCU when no optional cooling unit is in use.

DI6 RESET Supply module reset. 1: Reset. Not connected as default. Fault reset can be given from control panel.

DIIL Not in use Not in use as default. Not in use as default.

RO1 CHARGING On/off control of charging contactor. 1: On. Charging circuit control relay

RO2 LCU ON / OFF Liquid cooling unit on/off control. 1: On. Cooling unit control relay. Not connected when no optional cooling unit (+C139, +C140 or +C141) is in use.

RO3 MAIN CONTACTOR CONTROL

Main breaker/contactor control. 1: On. Breaker control circuit


46

Connections to standard I/O terminals

X20

1 VREF- Reference voltage -10 V DC, 1 kohm < RL < 10 kohm2 AGND

X21

1 VREF+ Reference voltage 10 V DC, 1 kohm < RL < 10 kohm2 AGND

3 AI1+ Not in use. 1) 0(2)…10 V, Rin > 200 kohm

4 AI1-

5 AI2+ Not in use. 1) 0(4)…20 mA, Rin = 100 ohm

6 AI2-

7 AI3+ Not in use. 1) 0(4)…20 mA, Rin = 100 ohm

8 AI3-

9 AO1+ Not in use. 1) 0(4)…20 mA, RL < 700 ohm

10 AO1-

11 AO2+ Not in use. 1) 0(4)…20 mA, RL < 700 ohm

12 AO2-

X22

1 DI1 Alarm / Fault

2 DI2 On/Off

3 DI3 Acknowledgement of main contactor

4 DI4 Ground fault 1)

5 DI5 Alarm/Fault 1)

6 DI6 Reset 1)

7 +24V +24 V DC max. 100 mA

8 +24V

9 DGND1 Digital ground

10 DGND2 Digital ground

11 DIIL Not in use 1)

X23

1 +24V Auxiliary voltage output, non-isolated, 24 V DC 250 mA2 GND

X25

1 RO1 Charging contactor control: open (0) / close (1)2 RO1

3 RO1

X26

1 RO2 LCU control: off (0) / on (1)

2 RO2

3 RO2

X27

1 RO3 Main breaker/contactor control: open (0) / close (1)2 RO3

3 RO3

1) Not in use as default.

For details, see the delivery-specific circuit diagrams of the drive. The diagrams show: - supply unit on/off control- main breaker supervision and on/off control- charging contactor on/off control- optional auxiliary circuit wiring.

WARNING! Starting sequence ie, charging, acknowledgements, main breaker/contactor control and the supply unit start, follows a certain order. Never change the order by by-passing signals (using jumpers), etc. That will cause a malfunction that may damage the unit.

Terminal block size:

cables 0.3 to 3.3 mm2 (22 to 12 AWG)

Tightening torque:

0.2 to 0.4 N·m (0.2 to 0.3 lbf·ft)

START10

3

4

1

2

Control circuitry

Main breaker/contactor

Charging contactor

Operating switch


47

Control of the inverter unit and motor

As standard, the drive is equipped with one control panel (type CDP-312R) on the inverter module cubicle door. The user controls the motor with this control panel or through fieldbus when the control unit of the inverter unit is equipped with an optional fieldbus adapter module.

Control panel

The control panel is the user interface of the supply and inverter units of the drive, providing the essential controls such as Start/Stop/Direction/Reset/Reference, and the parameter settings for the control programs. The suffix “LM” on the control panel display denotes ACS800-17LC. More information on using the panel can be found in the inverter unit firmware manual delivered with the drive.

The control panel is wired to the supply unit and inverter unit using a Y-splitter.

Connections and use of the I/O in the inverter unit

See page 103.

Circuit boards

1) The RDCU is equipped with an auxiliary power interface board (RAPI) when not equipped with terminals for connecting external control voltage (option +G307). The RAPI ensures that the “POWER FAIL” function of the RMIO board can be carried out in case the 24 V auxiliary power to the RDCU is interrupted ie, the fault and alarm loggers have enough time to write collected data into the flash memory.

Abbr. Description

RDCU Drive control unit. Note that in units with several modules in parallel, there is a branching unit (APBU or NPBU) between the modules and the control unit. 1)

RMIO Control board

APOW Power supply board

NRED Voltage reduction board in 690 V units

AINT Main circuit interface board

AGDR Gate driver board (interface to IGBTs)


48

Type designation labels

Drive label

The type designation label of the drive includes an IEC rating, CE, C-UL US, and CSA markings, a type designation and a serial number, which allow individual recognition of each unit. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week respectively. The remaining digits complete the serial number so that there are no two units with the same serial number. The type designation label is located on the front cover. An example label is shown below.

Supply, inverter and brake module label

The type designation label of the converter module includes the ratings, valid markings, a type code and a serial number. The module label is attached to the front panel of the module.

1

23

No. Description

1 Ratings

2 Type designation. See section Type designation key (page 50).

3 Serial number


49

An example type designation label of the ACS800-104LC inverter, supply and brake module is shown below.

No. Description

1 Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial number so that there are no two units or modules with the same number.

2 Type code. See section Type designation key (page 50).

3 Valid markings

4 Ratings of converter module when in inverter use

5 Ratings of converter module when in supply module use

6 Ratings of converter module when in brake use

12

3

546


50

Type designation key

The type code of the drive is indicated on its type designation label. The type code contains information on the specifications and configuration of the drive. The first digits from left and separated with hyphens express the basic configuration, for example ACS800-17LC-0250-5. The optional selections are given thereafter, separated by plus signs, for example +L501. For more information refer to, ACS800-17LC Ordering information (3AXD10000006878), available on request.

Type code of the basic configuration

* When no options are selected: IP42 (UL Type 1), main switch disconnector (load switch and contactor in frames R7i+R7i and R8i+R8i or air circuit breaker in frames 2×R8i+2×R8i and up), aR fuses, 230 V AC control voltage, CDP312R Control Panel, EMC filter for 2nd environment (+E200), du/dt limitation by choke (frames R8i+R8i and up, +E205), common mode filter (+E208), Standard Control Program, bottom entry and exit of cables, cable lead-through entries, coated boards, CD containing all manuals, IEC approved components, RDCO-03 module for communication link between the supply and inverter modules. Note: The option codes of the basic configuration are not shown on the type designation label.

Option codes

Digit Name/Description Alternatives

1…6 Product series ACS800

8…11 Product type 17LC – Cabinet-installed liquid-cooled four-quadrant drive*

13…16 Size Refer to the rating tables, page 145

18 Voltage rating 4 – Voltage range 380…415 V AC

5 – Voltage range 440…500 V AC

7 – Voltage range 525…690 V AC

Class Code Description

Degree of protection B055 IP54 (UL Type 12). Not available with +C134.

Construction C121 Marine construction (reinforced mechanics and fastening, marking of conductors according to +G341, marine door handles, self extinctive materials)

C129 UL Listed (115 V AC auxiliary voltage, cable conduit entries, all components UL Listed or Recognized, max. supply voltage 600 V)

C134 CSA Approved (as +C129, with CSA approved components)

C139 Stand alone liquid cooling unit (195 kW)

C140 Single-pump liquid cooling unit (70 kW). The cooling unit will be connected to the line-up at the factory, pipe connection on the right side, DIN flanges, industrial water. Control panel CDP312R included on the cubicle door. ACS800-17LC-xxxx-5 units: External power supply for pump motors is required, refer to options +M633, +M634.

C141 Two-pumps liquid cooling unit (195 kW). The cooling unit will be connected to the line-up at the factory, pipe connection on the right side, DIN flanges, industrial water. Control panel CDP312R included on the cubicle door. ACS800-17LC-xxxx-5 units: External power supply for pump motors is required refer to options +M633, +M634.

C142 Bottom pipe connection

C144 Pipe connection on the left side of the cabinet. Not available with +C139 and +C140.

C145 ANSI flanges

C146 Sea water heat exchanger

C147 3-way valve for liquid cooling unit in an additional cubicle


51

Resistor braking D150 Brake choppers of type NBRW (for 690 V units only)

D151 Brake resistors in a separate IP21 cubicle. Available with +D150 only. Not available with +C129.

D152 3-phase brake choppers. Control panel CDP312R included on the cubicle door.

Filters E202 EMC filter for first environment TN (grounded) system, category C2. Not available for units with rated current Icont.max above 1000 A.

E205 du/dt filter for frame R7i

E206 Sine output filter. Air-cooled, IP21. Not available for +C121, +C129 or +C134.

E214 RFI filter for marine applications.

Line options F271 Knobs for grounding the AC output busbars temporarily. Available with +H359 only.

F259 Grounding switch. Not available with options +C129 and +C134 or frames R7i+R7i and R8i+R8i.

F269 Output contactor. Available for ACS800-17LC-0870-3, -1030-5 and -1240-7 and larger units.

Heaters and auxiliary control voltage

G300 Cabinet heater (external supply)

G304 115 V AC control voltage

G307 Terminals for connecting external control voltage (230 V AC or 115 V AC uninterruptible power supply)

G313 Output for motor heater (external supply)

Materials G330 Halogen-free wiring and materials. Not available with +C129 and +C134.

Push buttons G331 Emergency stop push button (red) and reset button (blue lighted) on the cabinet door

Meters G335 A-meter in one phase

3G335 A-meter in three phases

G334 V-meter with selector switch

Wire markings G338 Equipment pin numbers are printed on wires between modules and on wires connected to equipment.

G339 Equipment and terminal block pin numbers are printed on wires between modules and on wires connected to equipment and terminal blocks. Main circuit conductors are marked.

G340 Equipment pin numbers are marked with rings on wires between modules and on wires connected to equipment, terminal blocks and detachable screw terminals. Main circuit conductors are marked.

G341 Equipment identifications and terminal block pin numbers are marked by rings on optical fibers, on wires between modules, and on wires connected to equipment, terminal blocks and detachable screw terminals. Main circuit conductors and also short and obvious connections are marked.

G342 Equipment identifications and terminal block pin numbers and remote addresses are marked by rings on optical fibers, on wires between modules, and on wires connected to equipment, terminal blocks and detachable screw terminals. Main circuit conductors and also short and obvious connections are marked.

Cabling H351 Top entry of cables

H353 Top exit of cables

H358 Cable gland plates (steel 3 mm, undrilled)

H359 Motor cable terminal cubicle

H364 Cable gland plates (aluminium 3 mm, undrilled)

H365 Cable gland plates (brass 6 mm, undrilled)



52

Fieldbus adapter modules K... +K451: RDNA-01 DeviceNet™ adapter module+K452: RLON-01 LonWorks® adapter module+K453: NIBA-01 InterBus-S adapter module+K454: FPBA-01 PROFIBUS DP adapter module+K455: NMBA-01Modbus Plus+K457: RCAN-01 CANopen adapter module+K458: RMBA-01 Modbus adapter module+K462: RCNA-01 ControlNet™ adapter module+K466: RETA-01 Ethernet adapter module (EIP, MB/TCP) +K467: RETA-02 Ethernet adapter module (PROFINET IO, Modbus TCP)+K469: RECA-01 EtherCAT adapter module+K470: REPL-01 Ethernet POWERLINK adapter module

I/O extensions and feedback interfaces

L... +L500: RAIO-01 analog I/O extension module+L501: RDIO-01 digital I/O extension module+L502: RTAC-01 pulse encoder interface+L504: Additional I/O terminal block+L505: PTC thermistor relay (one or two pcs). Not available with +L506 or +L513.+L506: Pt100 relay ( three, five or eight pcs). Not available with +L506 or +L513.+L508: RDCO-01 DDCS communication module +L509: RDCO-02 DDCS communication module +L513: ATEX-certified thermal protection interface for PTC thermistor relays. Available with +Q950 only.+L517: RTAC-03 pulse encoder interface (TTL) module

Starter for auxiliary motor fan (M600 to M605) and terminals for external voltage supply for liquid cooling unit’s pump

M600 Trip limit setting range: 1…1.6 A

M601 Trip limit setting range: 1.6…2.5 A

M602 Trip limit setting range: 2.5…4 A

M603 Trip limit setting range: 4…6.3 A

M604 Trip limit setting range: 6.3…10 A

M605 Trip limit setting range: 10…16 A

M633 Terminals for 380…415 V 50 Hz or 380…480 V 60 Hz external power supply of the liquid cooling unit’s pump

M634 Terminals for 660…690 V 50 Hz or 660…690 V 60 Hz external power supply of the liquid cooling unit’s pump

Programs and functions in memory unit

N... +N651: Master follower program (includes fiber optic cables). Available with +L509 only.+N653: Application base control program+N655: PCP/ESP control program+N660: Inline control program+N661: Winder control program+N669: Centrifuge control program+N671: System control program+N673: Special control program+N675: Rod pump control program+N677: Permanent magnet synchronous machine control program+N678: Test bench control program+N679: Standard control program+N682: Multi block programming program+N685: Motion control program+N687: Pump control program+N697: Crane control program+N698: Winch control program

Specialities P902 Customized

P904 Extended warranty

P913 Special color



53

Paper manuals R… +R700: English+R701: German+R702: Italian+R705: Swedish+R706: Finnish+R707: French

Note: The delivered manual set may include manuals in English if the translation is not available.

Safety Q950 Prevention of unexpected start

Q951 Emergency stop of Category 0 with opening the main breaker/contactor, see also +G331

Q952 Emergency stop of Category 1 with opening the main breaker/contactor, see also +G331

Q954 Ground fault monitoring for IT (ungrounded) systems

Q963 Emergency stop of Category 0 without opening the main breaker/contactor, see also +G331

Q964 Emergency stop of Category 1 without opening the main breaker/contactor, see also +G331

Q959 Supply transformer breaker disconnecting push button (red) on cabinet door

Q968 Safe torque off function with safety relay



54


55



This chapter describes the mechanical installation procedure of the drive.

Checking the installation site

See Ambient conditions on page 162 for allowable operating conditions, and Dimensions, weights and free space requirements on page 152 for requirements for free space around the unit.

The unit must be installed in an upright vertical position.

The floor that the unit is installed on must be of non-flammable material, as smooth as possible, and strong enough to support the weight of the unit. The floor flatness must be checked with a spirit level before the installation of the cabinets into their final position. The maximum allowed deviation from the surface level is 5 mm in every 3 metres. The installation site should be levelled, if necessary, as the cabinet is not equipped with adjustable feet.

The wall behind the unit must be of non-flammable material.

Note: Wide cabinet line-ups are delivered as “shipping splits”.

Required tools

The tools required for moving the unit to its final position, fastening it to the floor and tightening the connections are listed below.

• crane, fork-lift or pallet truck (check load capacity!); iron bar, jack and rollers

• Pozidrive and Torx (2.5–6 mm) screwdrivers for the tightening of the frame screws

• torque wrench

• set of wrenches or sockets for joining shipping splits.


56

Checking the delivery

The drive delivery contains:

• drive cabinet line-up

• optional modules (if ordered) installed into the control rack at the factory

• winch for the supply and inverter module replacement (if ordered)

• installation stand (delivered in a separate pallet)

• appropriate drive and optional module manuals

• delivery documents.

Check that there are no signs of damage. Before attempting installation and operation, check the information on the type designation label of the drive to verify that the delivery is of the correct type. See Type designation key on page 50.

Moving the unit

Moving the unit by craneUse the steel lifting bars attached to the top of the cabinet. Insert the lifting ropes or slings into the holes of the lifting bars.

The lifting bars can be removed (not mandatory) once the cabinet is in its final position. If the lifting bars are removed, the bolts must be refastened to retain the degree of protection of the cabinet.


57

Moving the unit by fork-lift or pallet truck

Moving the unit on rollers (not allowed with marine cabinets)

Laying the unit on its back

It is not allowed to transport or lay the unit on its back.

The centre of gravity is high. Be therefore careful when transporting the unit. Avoid tilting the cabinets.

The units are to be moved only in the upright position.

If using a pallet truck, check its load capacity before attempting to move the unit.

Remove the wooden bottom frame which is part of the shipment.

Lay the unit on the rollers and move it carefully until close to its final location.

Remove the rollers by lifting the unit with a crane, fork-lift, pallet truck or jack as described above.


58

Placing the unit

The cabinet can be moved into its final position with an iron bar and a wooden piece at the bottom edge of the cabinet. Care is to be taken to properly place the wooden piece so as not to damage the cabinet frame.


59

Overview of the installation procedure

This section contains a brief description of the installation procedure. See the detailed instructions refered to on each step.

(1) The cabinet can be installed with its back against a wall, or back-to-back with another unit. Fasten the unit (or first shipping split) to the floor. See Fastening the cabinet to the floor and wall (non-marine units) on page 60, or Fastening the unit to the floor and wall (marine units, option +C121) on page 62.

Note: A minimum clearance of 400 mm above the basic roof level of the cabinet is required to allow pressure release lids to open at an arc fault.

Note: Leave some space at the side where the cabinet outmost hinges are to allow the doors to open sufficiently (1a). The doors must open 120° to allow supply and inverter module replacement.

Note: Any height adjustment must be done before fastening the units or shipping splits together. Height adjustment can be done by using metal shims between the bottom frame and floor.

(2) Remove the lifting bars. Use the original bolts to block any unused holes. In marine units, use the holes for fastening the cabinet from top.

(3) Slide Axilock connectors onto the liquid pipe ends. One connector per pipe.

(4) If the line-up consists of shipping splits, fasten the first split to the second, see Joining the shipping splits on page 63. Each shipping split includes a joining cubicle where the busbars connect to the next split.

(5) Fasten the second shipping split to the floor.

(6) Join the DC busbars (a) and the PE busbars (b), liquid pipes and the loose wire ends in the joining cubicle, see Connecting the DC busbars on page 65 and Connecting the liquid pipes on page 64.

(7) Repeat steps (2) to (6) for the remaining shipping splits.

1

5

4

2

> 400 mm (15.75”)

Top clearances

3

> 320 mm (12.3”) for units with fan on roof (option +E206)

6b

6a

1a 1a


60

Fastening the cabinet to the floor and wall (non-marine units)

Fasten the cabinet to the floor by using clamps along the edge of the cabinet bottom, or by bolting the cabinet to the floor through the holes inside.

Alternative 1 – Clamping

Insert the clamps into the twin slots along the front and rear edges of the cabinet frame body and fasten them to the floor with a bolt. The recommended maximum distance between the clamps is 800 mm (31.5”).

If there is not enough working space behind the cabinet for mounting, replace the lifting bars at the top with L-brackets (not included) and fasten the top of the cabinet to the wall.

Clamp dimensions in millimetres

Cabinet frame

Distances between slots

Cubicle Width (mm)

Distance in millimetres and (inches)

300 150 (5.9”)

400 250 (9.85”)

500 350 (13.78”)

600 450 (17.72”)

700 550 (21.65”)

800 650 (25.6”)

Cabinet frame

Fastening the cabinet at the top when floor mounting from back is not possible (side view)

L-bracket

M16 screw

Cabinet top

Slot detail, front view (dimensions in millimetres)

Side view

View from above


61

Alternative 2 – Using the holes inside the cabinet

The cabinet can be fastened to the floor using the fastening holes inside the cabinet, if they are accessible. The recommended maximum distance between the fastening points is 800 mm (31.5”).

If there is not enough working space behind the cabinet for mounting, replace the lifting lugs at the top with L-brackets (not included) and fasten the top of the cabinet to the wall.

Fastening holes inside the cabinet (arrowed)

25

mm

(0

.98

5”)

Distances between the bottom fastening holes

Bolt size: M10 to M12 (3/8” to 1/2”)

Cubicle Width

Distance between holes

300 150 mm (5.9”)

400 250 (9.85”)

600 450 (17.7”)

700 550 (21.65”)

800 650 (25.6”)

OuterØ31 mm (1.22”)

Fastening the cabinet at the top when floor mounting from back is not possible (side view)

L-bracket

M16 screw

Cabinet top


62

Fastening the unit to the floor and wall (marine units, option +C121)

1. Bolt the cabinet to the floor through the holes in each flat bar at the base of the cabinet using M10 or M12 screws. Note: Welding is not recommended, see page 67.

2. If there is not enough room behind the cabinet for installation, clamp the rear ends of the flat bars.

3. Remove the lifting bars and fasten the top of the cabinet to the rear wall and/or roof using brackets.

1

23

Cabinet roof

M16 bolt

L-bracketBack panel of cabinet

Flat bars at base of cabinet

Clamps (not included in delivery)


63

Joining the shipping splits

All necessary materials for connecting the shipping splits together are located in the joining cubicle. Join the shipping splits in the following order.

Preparing the liquid pipe connections

Slide Axilock connectors onto the liquid pipes. Note: when the cabinets are pushed together the pipe ends come too close to each other and the connectors cannot be installed any more.

Fastening the cabinets together

Two shipping splits are joined in a joining cubicle. Special M6 screws for fastening the shipping splits together are enclosed in a plastic bag inside the cabinet. The threaded bushings are already mounted on the post.

Fasten the front post and the rear post of the joining section with 7 screws to the posts of the next cubicle.

Maximum tightening torque: 5 N·m (3 lbf·ft)

7× 7×


64

Connecting the liquid pipes

1. Ensure the Axilock connectors are slid on pipe ends. See section Preparing the liquid pipe connections on page 63.

2. Position the liquid pipe ends against each other.

3. Centre the Axilock connector onto the pipe ends.

4. Tighten the connector bolts to a torque shown on the label attached to the connector.

Connecting the PE busbars

Connect the PE busbars as shown below.

Parallel misalignment: max 3 mm (0.2”)

Angular error: max 2° in any direction

Axial gap: 5 to 15 mm (0.2” to 0.6”)

2 3

Tightening torque: 35–40 N·m (25–30 lbf·ft)Strength class: 8.8

Spring washerPlain washer

Plain washer

M10


65

Connecting the DC busbars

Connect the main DC busbars from front as follows:

1. Remove the metal plate covering the busbars in the joining cubicle.

2. Unscrew the bolts of the joint pieces (a).

3. Connect the busbars with the joint pieces (a). Tighten the bolts to 55–70 N·m (40–50 lbf·ft). Bolt strength class: 8.8.

4. Refit the covering plate.

WARNING! Do not place the spring washer against the joint piece. Use the plain washer (with electroplated zinc coating and blue passivation) instead. An unpassivated zinc-coated spring washer positioned directly against the joint piece would cause corrosion.

a

Side views of busbar connection

a) joint piece, b) plain washer with electroplated zinc coating and blue chromate passivation, c) spring washer with mechanically sprayed zinc coating, d) nut

a

aa

aa

aa

aa

aa

ab

ac

ad


66

Miscellaneous

Cable duct in the floor below the cabinet

A cable duct can be constructed below the middle part of the cabinet. The duct width may not exceed 450 mm. The cabinet weight lies on the 100 mm wide section in front and 50 mm wide section at the back which the floor must carry.

Viewed from above Side view

This area can be used for a cable duct

Prevent the cooling air flow from the cable duct to the cabinet by bottom plates. To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit. With user-defined cable entries, take care of the degree of protection, fire protection and EMC compliance. Cables

50 mm 100 mm

Front

Front

Minimum widths for the floor support


67

Electric welding

It is not recommended to fasten the cabinet by welding. If the other fastening methods cannot be used, follow the welding instructions below.

Cabinets without flat bars at the base

• Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 metres of the welding point.

Cabinets with flat bars at the base

• Weld only the flat bar under the cabinet, never the cabinet frame itself.

• Clamp the welding electrode onto the flat bar about to be welded or to the next flat bar within 0.5 metres of the welding point.

WARNING! If the welding return wire is connected improperly, the welding circuit may damage electronic circuits in the cabinet. The thickness of the zinc coating of the cabinet frame is 100 to 200 micrometres; on the flat bars the coating is approximately 20 micrometres. Ensure that the welding fumes are not inhaled.


68


69



This chapter contains the instructions that you must follow when selecting the motor, the cables, the protections, the cable routing and the way of operation for the drive system.

Note: The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

Selecting the supply disconnecting device (disconnecting means)

The drive is equipped with a main switch disconnector as standard.

Checking the compatibility of the motor and drive

Use an AC induction motor or a permanent magnet synchronous motor with the drive. Several induction motors can be connected at a time but only one permanent magnet motor. Controlling a permanent magnet motor is only allowed using the ACS800 permanent magnet synchronous machine control program or other application programs in scalar control mode.

Select the motor and drive according to the rating tables in chapter Technical data. Use the DriveSize PC tool if the default load cycles are not applicable.

1. Check that the motor ratings lie within the allowed ranges of the drive control program:

• motor nominal voltage is in the range of 1/2 … 2 · UN

• motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control and 0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.


70

2. Check that the motor voltage rating meets the application requirements:

See section When DC link voltage is increased with parameter settings (page 73).

3. Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from the AC power source voltage.

4. Ensure that the motor insulation system withstands the maximum peak voltage in the motor terminals. See section Requirements for motor insulation and bearings and drive filters below for the required motor insulation system and drive filtering.

Example: When the supply voltage is 440 V, the maximum peak voltage in the motor terminals can be approximated as follows: 440 V × 1.41 × 2 = 1241 V. Check that the motor insulation system withstands this voltage.

Protecting the motor insulation and bearings

The drive employs modern IGBT inverter technology. Regardless of frequency, the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time. The pulse voltage can almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals. This can cause additional stress on the motor and motor cable insulation.

Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings, which can gradually erode the bearing races and rolling elements.

Optional du/dt filters protect motor insulation system and reduce bearing currents. Common mode filters mainly reduce bearing currents.

To avoid damage to motor bearings:

• select and install the cables according to the instructions given in the hardware manual

• use insulated N-end (non-drive end) bearings and output filters from ABB according to section Requirements for motor insulation and bearings and drive filters below.

When … then the motor voltage rating should be …

DC link voltage is not increased from nominal (through parameter settings)

UN

DC link voltage is increased from nominal (through parameter settings)

UDC / 1.41

UN Rated input voltage of drive

UDC Maximum DC link voltage of drive in V DC. See the parameter setting. For resistor braking, UDC = 1.21 × nominal DC link voltage. Note: Nominal DC link voltage is UN × 1.41 in V DC.


71

Requirements for motor insulation and bearings and drive filters

The following table shows how to select the motor insulation system and when an optional ABB du/dt filter, insulated N-end (non-drive end) motor bearings and ABB common mode filters are required. The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors. Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty.

Ma

nu

fac

ture

r

Motor type Nominal AC line voltage

Requirement for

Motor insulation system

ABB du/dt filter, insulated N-end bearing and ABB common mode filter

PN < 100 kW

and

frame size < IEC 315

100 kW < PN < 350 kW or

frame size > IEC 315

PN > 350 kW

or


PN < 134 hp

and frame size < NEMA 500

134 hp < PN < 469 hp

or frame size > NEMA 500

PN > 469 hp


A

B

B

Random-wound M2_ M3_ and M4_

UN < 500 V Standard - + N + N + CMF

500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF

or

Reinforced - + N + N + CMF

600 V < UN < 690 V

(cable length < 150 m)

Reinforced + du/dt + du/dt + N + du/dt + N + CMF

600 V < UN < 690 V (cable length > 150 m)


Form-wound HX_ and AM_

380 V < UN < 690 V Standard n.a. + N + CMF PN < 500 kW: + N + CMF

PN > 500 kW: + N + CMF + du/dt

Old* form-wound HX_ and modular

380 V < UN < 690 V Check with the motor manufacturer.

+ du/dt with voltages over 500 V + N + CMF

Random-wound HX_ and AM_ **

0 V < UN < 500 V Enamelled wire with fiber glass taping

+ N + CMF

500 V < UN < 690 V + du/dt + N + CMF


72

* manufactured before 1.1.1998

** For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.

*** If the intermediate DC circuit voltage of the drive is increased from the nominal level, check with the motor manufacturer if additional output filters are needed in the applied drive operation range.

Note 1: The abbreviations used in the table are defined below.

Explosion-safe (EX) motors

Consult the motor manufacturer regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors.

N

O

N

-

A

B

B

Random-wound and form-wound

UN < 420 V Standard: ÛLL = 1300 V

- + N or CMF + N + CMF

420 V < UN < 500 V Standard: ÛLL = 1300 V

+ du/dt + du/dt + N + du/dt + N + CMF

or

+ du/dt + CMF

or

Reinforced: ÛLL = 1600 V, 0.2 microsecond rise time


500 V < UN < 600 V Reinforced: ÛLL = 1600 V


or

+ du/dt + CMF

or

Reinforced: ÛLL = 1800 V


600 V < UN < 690 V Reinforced: ÛLL = 1800 V


Reinforced: ÛLL = 2000 V, 0.3 microsecond rise time ***

- N + CMF N + CMF

Abbreviation Definition

UN Nominal voltage of the supply network

ÛLL Peak line-to-line voltage at motor terminals which the motor insulation must withstand

PN Motor nominal power

du/dt du/dt filter at the output of the drive +E205

CMF Common mode filter +E208

N N-end bearing: insulated motor non-drive end bearing

n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.

Ma

nu

fac

ture

r

Motor type Nominal AC line voltage

Requirement for



PN < 100 kW

and

frame size < IEC 315

100 kW < PN < 350 kW or


PN > 350 kW

or


PN < 134 hp

and frame size < NEMA 500

134 hp < PN < 469 hp


PN > 469 hp



73

High-output motors and IP 23 motors

For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001) and for IP23 motors, the requirements of ABB random-wound motor series (for example M3AA, M3AP, M3BP) are given below. For non-ABB motor types, see the basic table above and apply the requirements of range 100 kW < PN < 350 kW to motors with PN < 100 kW. Apply the requirements of range PN > 350 kW to motors within the range 100 kW < PN < 350 kW. In other cases, consult the motor manufacturer.

HXR and AMA motors

All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR machines manufactured in Helsinki starting 1.1.1998 have form-wound windings.

ABB motors of types other than M2_, M3_, HX_ and AM_

Use the selection criteria given for non-ABB motors.

When DC link voltage is increased with parameter settings

If the intermediate circuit DC voltage is increased with the IGBT supply control program parameter settings, select the motor insulation system according to the increased DC voltage level, especially in the 500 V supply voltage range.

Calculating the rise time and the peak line-to-line voltage

The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length. The requirements for the motor insulation system given in the table are “worst case” requirements covering installations with 30 metre and longer cables. The rise time can be calculated as follows: t = 0.8 · ÛLL/(du/dt). Read ÛLL and du/dt from the diagrams below. Multiply the values of the graph by the supply voltage (UN). In case of drives with resistor braking, the ÛLL and du/dt values are approximately 20% higher.

Man

ufa

ctu

rer Motor type Nominal mains

voltage (AC line voltage)

Requirement for



PN < 100 kW 100 kW < PN < 200 kW PN > 200 kW

PN < 140 hp 140 hp < PN < 268 hp PN > 268 hp

A

B

B

Random-wound

UN < 500 V Standard - + N + N + CMF

500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF

or


600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF


74

Sine filters

Sine filters protect the motor insulation system. Therefore, a du/dt filter can be replaced with a sine filter. The peak phase-to-phase voltage with a sine filter is approximately 1.5 × UN.

Selecting the power cables

General rules

Dimension the input power and motor cables according to local regulations:

• Dimension the cable to carry the drive load current. See chapter Technical data for the rated currents.

• Select a cable rated for at least 70 °C maximum permissible temperature of conductor in continuous use. For US, see Additional US requirements, page 79.

• The inductance and impedance of the PE conductor/cable (grounding wire) must be rated according to permissible touch voltage appearing under fault conditions (so that the fault point voltage will not rise excessively when a ground fault occurs).

• 600 V AC cable is accepted for up to 500 V AC. For 690 V AC rated equipment, the rated voltage between the conductors of the cable should be minimum 1 kV.

Use symmetrical shielded motor cable, see page 76. Ground the shield(s) of motor cable(s) 360° at both ends.

Note: When continuous metal conduit is employed, shielded cable is not required. The conduit must have bonding at both ends as with cable shield.

A four-conductor system is allowed for input cabling, but shielded symmetrical cable is recommended.

ÛLL/UN

Without du/dt Filter

Cable length (m)

du/dtUN

-------------(1/μs)

1.0

2.0

5.0

4.0

3.0

1.5

2.5

3.5

4.5

100 200 300100 200 3000.0

0.5

1.0

1.5

2.0

2.5

3.0

Cable length (m)

With du/dt Filter

du/dtUN

-------------(1/μs)

ÛLL/UN

5.5


75

To operate as a protective conductor, the shield conductivity requirements according to IEC 60439-1 are shown below when the protective conductor is made of the same metal as the phase conductors. The table applies also to four-conductor systems.

Compared to a four-conductor system, the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear.

Note: The cabinet configuration of the drive may require multiple supply and/or motor cabling. Refer to the connection diagrams in chapter Electrical installation.

Keep the motor cable and its PE pigtail (twisted screen) as short as possible in order to reduce high-frequency electromagnetic emissions.

Cross-sectional area of the phase conductors

S (mm2)

Minimum cross-sectional area of the corresponding protective conductor

Sp (mm2)

S < 16 S

16 < S < 35 16

35 < S < 400 S/2

400 < S < 800 200

800 < S S/4


76

Typical power cable sizes

Tables below give current carrying capacity (ILmax) for aluminium and copper PVC/XLPE insulated cables. A correction factor K = 0.70 is used (cables laid on the cable trays side by side, max 9 cables per tray, three ladder type trays one on top of the other, ambient temperature 30°C, EN 60204-1 and IEC 364-5-52).

Aluminium cable PVC insulation

Conductor temperature 70°

XLPE insulation


Size ø [mm] ILmax [A] Time const. [s] ILmax [A] Time const. [s]

3 × 35 + 10 Cu

3 × 50 + 15 Cu

3 × 70 + 21 Cu

3 × 95 + 29 Cu

3 × 120 + 41 Cu

3 × 150 + 41 Cu

3 × 185 + 57 Cu

3 × 240 + 72 Cu

26

29

32

38

41

44

49

54

69

83

107

130

151

174

199

235

677

912

1110

1412

1665

1920

2257

2683

86

104

134

163

189

218

249

294

677

912

1110

1412

1665

1920

2257

2683

2 × (3 × 70 + 21 Cu)

2 × (3 × 95 + 29 Cu)

2 × (3 × 120 + 41 Cu)

2 × (3 × 150 + 41 Cu)

2 × (3 × 185 + 57 Cu)

2 × (3 × 240 + 72 Cu)

2 × 32

2 × 38

2 × 41

2 × 44

2 × 49

2 × 54

214

260

302

348

398

470

1110

1412

1665

1920

2257

2683

268

325

378

435

498

588

1110

1412

1665

1920

2257

2683

3 × (3 × 150 + 41 Cu)

3 × (3 × 185 + 57 Cu)

3 × (3 × 240 + 72 Cu)

3 × 44

3 × 49

3 × 54

522

597

705

1920

2257

2683

652

746

881

1920

2257

2683

4 × (3 × 185 + 57 Cu)

4 × (3 × 240 + 72 Cu)

4 × 49

4 × 54

796

940

2257

2683

995

1175

2257

2683

5 × (3 × 185 + 57 Cu)

5 × (3 × 240 + 72 Cu)

5 × 49

5 × 54

995

1175

2257

2683

1244

1469

2257

2683

6 × (3 × 240 + 72 Cu) 6 × 54 1410 2683 1763 2683

7 × (3 × 240 + 72 Cu) 7 × 54 1645 2683 2058 2683

8 × (3 × 240 + 72 Cu) 8 × 54 1880 2683 2350 2683

9 × (3 × 240 + 72 Cu) 9 × 54 2115 2683 2644 2683

10 × (3 × 240 + 72 Cu) 10 × 54 2350 2683 2938 2683


77

Copper cable PVC insulation


XLPE insulation


Size ø [mm] ILmax [A] Time const. [s] ILmax [A] Time const. [s]

3 × 1.5 + 1.5

3 × 2.5 + 2.5

(3 × 4 + 4)

3 × 6 + 6

3 × 10 + 10

3 × 16 + 16

3 × 25 + 16

3 × 35 + 16

3 × 50 + 25

3 × 70 + 35

3 × 95 + 50

3 × 120 + 70

3 × 150 + 70

3 × 185 + 95

3 × 240 + 120

13

14

16

18

21

23

24

26

29

32

38

41

44

50

55

13

18

24

30

42

56

71

88

107

137

167

193

223

255

301

85

123

177

255

354

505

773

970

1268

1554

1954

2313

2724

3186

3904

16

23

30

38

53

70

89

110

134

171

209

241

279

319

376

85

123

177

255

354

505

773

970

1268

1554

1954

2313

2724

3186

3904

2 × (3 × 70 + 35)

2 × (3 × 95 + 50)

2 × (3 × 120 + 70)

2 × (3 × 150 + 70)

2 × (3 × 185 + 95)

2 × (3 × 240 + 120)

2 × 32

2 × 38

2 × 41

2 × 44

2 × 50

2 × 55

274

334

386

446

510

602

1554

1954

2313

2724

3186

3904

343

418

483

558

638

753

1554

1954

2313

2724

3186

3904

3 × (3 × 120 + 70)

3 × (3 × 150 + 70)

3 × (3 × 185 + 95)

3 × (3 × 240 + 120)

3 × 41

3 × 44

3 × 50

3 × 55

579

669

765

903

2313

2724

3186

3904

724

836

956

1129

2313

2724

3186

3904

4 × (3 × 150 + 70)

4 × (3 × 185 + 95)

4 × (3 × 240 + 120)

4 × 44

4 × 50

4 × 55

892

1020

1204

2724

3186

3904

1115

1275

1505

2724

3186

3904

5 × (3 × 185 + 95)

5 × (3 × 240 + 120)

5 × 50

5 × 55

1275

1505

3186

3904

1594

1881

3186

3904

6 × (3 × 185 + 95)

6 × (3 × 240 + 120)

6 × 50

6 × 55

1530

1806

3186

3904

1913

2258

3186

3904

7 × (3 × 240 + 120) 7 × 55 2107 3904 2634 3904

8 × (3 × 240 + 120) 8 × 55 2408 3904 3010 3904


78

Alternative power cable types

Power cable types that can be used with the drive are represented below.

Motor cable shield

To effectively suppress radiated and conducted radio-frequency emissions, the shield conductivity must be at least 1/10 of the phase conductor conductivity. The requirements are easily met with a copper or aluminium shield. The minimum requirement of the motor cable shield of the drive is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape. The better and tighter the shield, the lower the emission level and the bearing currents.

Recommended: Symmetrical shielded cable: three phase conductors and a concentric or otherwise symmetrically constructed PE conductor, and a shield

PE conductor and shield

Shield Shield

A separate PE conductor is required if the conductivity of the cable shield is < 50 % of the conductivity of the phase conductor.

Shield

PE

PE

PE

Not allowed for motor cabling: A four-conductor system: three phase conductors and a protective conductor.

Not allowed: Symmetrical cable with individual shields for each phase conductor

Shield

PE

Insulation jacket Copper wire screen Helix of copper tape

Cable core

Inner insulation


79

Additional US requirements

Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable must be used for the motor cables if metallic conduit is not used. For the North American market, 600 V AC cable is accepted for up to 500 V AC. 1000 V AC cable is required above 500 V AC (below 600 V AC). For drives rated over 100 amperes, the power cables must be rated for 75 °C (167 °F).

Conduit

Where conduits must be coupled together, bridge the joint with a ground conductor bonded to the conduit on each side of the joint. Bond the conduits also to the drive enclosure. Use separate conduits for input power, motor, brake resistors, and control wiring. When conduit is employed, type MC continuous corrugated aluminum armor cable or shielded cable is not required. A dedicated ground cable is always required.

Note: Do not run motor wiring from more than one drive in the same conduit.

Armored cable / shielded power cable

6-conductor (3 phases and 3 ground) type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers (trade names in parentheses):

• Anixter Wire & Cable (Philsheath)

• BICC General Corp (Philsheath)

• Rockbestos Co. (Gardex)

• Oaknite (CLX).

Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and Pirelli, among others.

Selecting the control cables

General rules

All control cables must be shielded.

Use a double-shielded twisted pair cable (see figure a) for analogue signals. This type of cable is recommended for the pulse encoder signals also. Employ one individually shielded pair for each signal. Do not use common return for different analogue signals.


80

A double-shielded cable is the best alternative for low-voltage digital signals but single-shielded twisted multipair cable (figure b) is also usable.

Run analogue and digital signals in separate, shielded cables.

Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in the same cables as digital input signals. It is recommended that the relay-controlled signals be run as twisted pairs.

Never mix 24 V DC and 115 / 230 V AC signals in the same cable.

Relay cable

The cable type with braided metallic screen (e.g. ÖLFLEX LAPPKABEL, Germany) has been tested and approved by ABB.

Control panel cable

In remote use, the cable connecting the control panel to the drive must not exceed 3 metres (10 ft). The cable type tested and approved by ABB is used in control panel option kits.

Coaxial cable (for use with Advant Controllers AC 80/AC 800)

• 75 ohm

• RG59, diameter 7 mm or RG11, diameter 11 mm

• Maximum cable length: 300 m (1000 ft)

Routing the cables

Route the motor cable away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. It is recommended that the motor cable, input power cable and control cables be installed on separate trays. Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage.

Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible. Do not run extra cables through the drive.

The cable trays must have good electrical bonding to each other and to the grounding electrodes. Aluminium tray systems can be used to improve local equalizing of potential.

aDouble-shielded twisted pair cable

bSingle-shielded twisted multipair cable


81

A diagram of the cable routing is below.

Separate control cable ducts

Protecting the drive, input power cable, motor and motor cable in short circuit situation and against thermal overload

Protecting the drive and input power cable in short-circuit situations

Always protect the input cable with fuses. In networks with a short-circuit withstand of 65 kA or less, standard gG fuses can be used. No fuses need be installed at the drive input.

90 ° min 500 mm (20 in.)

Motor cable Input power cable

Control cables

min 200 mm (8 in.)

min 300 mm (12 in.)

Motor cable

Power cable

Drive

24 V 24 V230 V

Lead 24 V and 230 V (120 V) control cables in separate ducts inside the cabinet.

Not allowed unless the 24 V cable is insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V (120 V).

(120 V)230 V

(120 V)


82

If the drive is supplied through busbars, fuses must be installed at the drive input. In networks with a short-circuit withstand of less than 50 kA, standard gG fuses are sufficient. If the network has a short-circuit withstand of 50…65 kA, aR fuses are required.

Size the fuses according to local safety regulations, appropriate input voltage and the rated current of the drive. Check that the operating time of the fuses is below 0.5 seconds. For fuse ratings, see chapter Technical data.

WARNING! Circuit breakers are not capable of providing sufficient protection because they are inherently slower than fuses. Always use fuses with circuit breakers.

Protecting the motor and motor cable in short-circuit situations

The drive protects the motor cable and the motor in a short-circuit situation when the motor cable is dimensioned according to the nominal current of the drive. No additional protection devices are needed.

Protecting the drive, motor cable and input power cable against thermal overload

The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. No additional thermal protection devices are needed.

WARNING! If the drive is connected to multiple motors, a separate thermal overload switch or a circuit breaker must be used for protecting each cable and motor. These devices may require a separate fuse to cut off the short-circuit current.

Protecting the motor against thermal overload

According to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary. Depending on a drive parameter value, the function either monitors a calculated temperature value (based on a motor thermal model) or an actual temperature indication given by motor temperature sensors. The user can tune the thermal model further by feeding in additional motor and load data.

The most common temperature sensors are:

• motor sizes IEC180…225: thermal switch eg, Klixon

• motor sizes IEC200…250 and larger: PTC or Pt100.

See the firmware manual for more information on the motor thermal protection, and the connection and use of the temperature sensors.


83

Insulation requirements for the motor temperature sensor circuit

WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non-conductive or conductive but not connected to the protective earth.

To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital inputs of the drive can be implemented in three alternate ways:

1. There is double or reinforced insulation between the thermistor and live parts of the motor.

2. Circuits connected to all digital and analogue inputs of the drive are protected against contact and insulated with basic insulation (the same voltage level as the drive main circuit) from other low voltage circuits.

3. An external thermistor relay is used. The insulation of the relay must be rated for the same voltage level as the main circuit of the drive. For connection, see the firmware manual.

Protecting the drive against ground faults in the drive, motor or motor cable

Both the supply unit and the inverter unit are equipped with an internal ground fault protective function to protect the drive against ground faults in the drive, motor and motor cable. (This is not a personnel safety or a fire protection feature.) Both ground fault protective functions can be disabled; refer to the IGBT Supply Control Program Firmware Manual (3AFE68315735 [English]) and the firmware manual of the drive control program respectively.

Note: The EMC filter (if present) includes capacitors connected between the main circuit and the frame. These capacitors and long motor cables increase the ground leakage current and may cause fault current circuit breakers to function.

Implementing the emergency stop function

The drive can be equipped with category 0 and 1 emergency stop options (+Q951, +Q952, +Q963 and +Q964). Install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed. Pressing the stop key ( ) on the control panel of the drive, or turning the operating switch of the drive from position “1” to “0” does not generate an emergency stop of the motor or separate the drive from dangerous potential.

For more information, see Wiring, start-up and operation instructions of safety options (+Q950, +Q951, +Q952, +Q963, +Q964, +Q967 and +Q968) for ACS800 cabinet-installed drives (3AUA0000026238 [English]).


84

Implementing the Prevention of unexpected start function

The drive equipped with option +Q950 supports the Prevention of unexpected start function according to standards IEC/EN 60204-1:1997; ISO/DIS 14118:1996 and EN 1037:1996. The circuit conforms to EN 954-1, Category 3.

The Prevention of unexpected start function disables the control voltage of the power semiconductors of the drive output stage, thus preventing the motor-side converter from generating the voltage required to rotate the motor. By using this function, short-time operations (like cleaning) and/or maintenance work on non-electrical parts of the machinery can be performed without switching off the power supply to the drive.

The operator activates the prevention of unexpected start function using a switch mounted on a control desk. When the function is activated, the switch is opened, and an indicator lamp will light.

WARNING! The prevention of unexpected start function does not disconnect the voltage of the main and auxiliary circuits from the drive. Therefore maintenance work on electrical parts of the drive can only be carried out after isolating the drive system from the main supply.

Note: If a running drive is stopped by using the Prevention of unexpected start function, the drive will cut off the motor supply voltage and the motor will coast to stop.



85

Implementing the Safe torque off function

Safe torque off with safety relay option (+Q968) is available for the drive. It provides Safe torque off (STO) function according to standards EN 61800-5-2:2007; EN ISO 13849-1:2008, IEC 61508 and EN 62061:2005. The function also corresponds to an uncontrolled stop in accordance with stop category 0 of EN 60204-1 and prevention of unexpected start-up of EN 1037.

The Safe torque off function disables the control voltage of the power semiconductors of the drive output stage, thus preventing the inverter from generating the voltage required to rotate the motor (see diagram below). By using this function, short-time operations (like cleaning) and/or maintenance work on non-electrical parts of the machinery can be performed without switching off the power supply to the drive.

WARNING! The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive. Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply.

Note: It is not recommended to stop the drive by using the Safe torque off function. If a running drive is stopped by using the Safe torque off function, the drive will stop by coasting. If this causes danger or is not acceptable, the drive and machinery must be stopped using the appropriate stopping mode before using the Safe torque off function.

Note concerning permanent magnet motor drives in case of a multiple IGBT power semiconductor failure: In spite of the activation of the Safe torque off function, the drive system can produce an alignment torque which maximally rotates the motor shaft by 180/p degrees. p denotes the pole pair number.


Implementing the power-loss ride-through function

The power loss ride-through is not available as an standard option (on the price list). However, the supply unit control program supports the function, and it can be implemented in most cases if ordered separately as an engineered option for the delivery.

Supplying power for the auxiliary circuits

Drives of frame sizes R7i+R7i and R8i+R8i are equipped with an auxiliary control voltage transformer which supplies 230 V AC voltage to cooling fans and control circuits. With option +G304 the supplied voltage is 115 V AC.


86

Drives of frame sizes 2×R8i+2×R8i and up can be equipped with an optional auxiliary control voltage transformer which supplies 230 V AC voltage to cooling fans and control circuits. With option +G304 the supplied voltage is 115 V AC.

The drive can be equipped with terminals for uninterruptible power supply (option +G307). The circuit ensures voltage for control circuit relays and RMIO boards. The cooling fans are not supplied.

Terminals for connecting external control voltage (option +G307)

• See section Connecting external power supply for the auxiliary circuits on page 100 for the connection.

• Calculate load using data given in section Auxiliary circuit current consumption on page 164. Consider only “non-fan” load.

Units without optional auxiliary control transformer and without terminals for connecting external control voltage (option +G307)

• See section Connecting external power supply for the auxiliary circuits on page 100 for the connection.

• Calculate load using data given in section Auxiliary circuit current consumption on page 164.

Using power factor compensation capacitors with the drive

Power factor compensation is not needed with AC drives. However, if a drive is to be connected in a system with compensation capacitors installed, note the following restrictions.

WARNING! Do not connect power factor compensation capacitors to the motor cables (between the drive and the motor). They are not intended for use with AC drives and can cause permanent damage to the drive or themselves.

If there are power factor compensation capacitors in parallel with the 3-phase input of the drive:

1. Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may trip or even damage the drive.

2. If capacitor load is increased/decreased step by step when the AC drive is connected to the power line, ensure that the connection steps are low enough not to cause voltage transients that would trip the drive.

3. Check that the power factor compensation unit is suitable for use in systems with AC drives i.e. harmonic generating loads. In such systems, the compensation unit should typically be equipped with a blocking reactor or harmonic filter.


87

Implementing a safety switch between the drive and motor

It is recommended to install a safety switch between the permanent magnet synchronous motor and the drive output. The switch is needed to isolate the motor during any maintenance work on the drive.

Using a contactor between the drive and motor

Implementing the control of an output contactor depends on how you select the drive to operate. See also section Implementing a bypass connection on page 88.

When you have selected to use

• DTC or vector motor control mode, and motor ramp stop,

open the contactor as follows:

1. Give a stop command to the drive.

2. Wait until the drive decelerates the motor to zero speed.

3. Open the contactor.

When you have selected to use

• DTC or vector motor control mode, and motor coast stop, or

• scalar control mode,

open the contactor as follows:

1. Give a stop command to the drive.

2. Open the contactor.

WARNING! When the DTC or vector motor control mode is in use, never open the output contactor while the drive controls the motor. The DTC and vector motor control operate extremely fast, much faster than it takes for the contactor to open its contacts. When the contactor starts opening while the drive controls the motor, the DTC or vector control will try to maintain the load current by immediately increasing the drive output voltage to the maximum. This will damage, or even burn the contactor completely.


88

Implementing a bypass connection

If bypassing is required, employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line. Ensure with interlocking that the contactors cannot be closed simultaneously.

WARNING! Never connect the supply power to the drive output terminals U2, V2 and W2. Line voltage applied to the output can result in permanent damage to the unit.

Example bypass connection

An example bypass connection is shown below.

Switching the motor power supply from drive to direct-on-line

1. Stop the drive and the motor with the drive control panel (drive in local control mode) or the external stop signal (drive in remote control mode).

2. Open the main contactor of the drive with S11.

Description

Q1 Drive main switch

Q4 Bypass circuit breaker

K1 Drive main contactor

K4 Bypass contactor

K5 Drive output contactor

S11 Drive main contactor on/off control

S40 Motor power supply selection (drive or direct-on-line)

S41 Start when motor is connected direct-on-line

S42 Stop when motor is connected direct-on-line


89

3. Switch the motor power supply from the drive to direct-on-line with S40.

4. Wait for 10 seconds to allow the motor magnetization to die away.

5. Start the motor with S41.

Switching the motor power supply from direct-on-line to drive

1. Stop the motor with S42.

2. Switch the motor power supply from direct-on-line to the drive with S40.

3. Close the main contactor of the drive with switch S11 (-> turn to position ST for two seconds and leave to position 1).

4. Start the drive and the motor with the drive control panel (drive in local control mode) or the external start signal (drive in remote control mode).

Protecting the contacts of relay outputs

Inductive loads (such as relays, contactors, motors) cause voltage transients when switched off.

The relay contacts of the RMIO board are protected with varistors (250 V) against overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) in order to minimize the EMC emission at switch-off. If not suppressed, the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system.

Install the protective component as close to the inductive load as possible. Do not install the protective components at the terminal block.

24 V DC

230 V AC

230 V AC

Varistor

RC filter

Diode

RO (NC)

RO (C)

RO (NO)

RO (NC)

RO (C)

RO (NO)

RO (NC)

RO (C)

RO (NO)

Relay outputs


90

Considering the PELV on installation sites above 2000 metres (6562 feet)

WARNING! Wear appropriate protection when installing, operating or servicing the RMIO board wiring and optional modules attached to the board. The Protective Extra Low Voltage (PELV) requirements stated in EN 61800-5-1 are not fulfilled at altitudes above 2000 m (6562 ft).


91



This chapter describes the electrical installation procedure of the drive.

WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.

WARNING! During the installation procedure, inverter modules may have to be temporarily extracted from the cabinet. The modules have a high centre of gravity.

Checking the insulation of the assembly

Drive

Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive. Every drive has been tested for insulation between the main circuit and the chassis at the factory. Also, there are voltage-limiting circuits inside the drive which cut down the testing voltage automatically.

Supply cable

Check the insulation of the supply (input) cable according to local regulations before connecting to the drive.

Motor and motor cable

Check the insulation of the motor and motor cable as follows:

1. Check that the motor cable is connected to the motor, and disconnected from the drive output terminals U2, V2 and W2.

2. Measure the insulation resistance between each phase conductor and then between each phase conductor and the Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, consult the manufacturer’s instructions.


92

Note: Moisture inside the motor casing will reduce the insulation resistance. If moisture is suspected, dry the motor and repeat the measurement.

Braking resistor assembly

Check the insulation of the braking resistor assembly (if present) as follows:

1. Check that the resistor cable is connected to the resistor, and disconnected from the drive output terminals R+ and R-.

2. At the drive end, connect the R+ and R- conductors of the resistor cable together. Measure the insulation resistance between the combined conductors and the PE conductor by using a measuring voltage of 1 kV DC. The insulation resistance must be higher than 1 Mohm.

Checking the compatibility with IT (ungrounded) and corner grounded TN systems

EMC filter +E202 is not suitable for use in an IT (ungrounded) system. If the drive is equipped with EMC filter +E202, disconnect the filter before connecting the drive to the supply network. For detailed instructions on how to do this, please contact your local ABB representative.

WARNING! If a drive with EMC filter +E202 is installed on an IT system (an ungrounded power system or a high resistance-grounded [over 30 ohm] power system), the system will be connected to earth potential through the EMC filter capacitors of the drive. This may cause danger, or damage the unit.

ohm

M3~

U1

V1

W1 PE

ohm

ohmR-

R+

PE


93

Connecting the input power cable

Connection diagram

A connection diagram of frame R7i and R8i units is shown below. The input cable connection for frames 2×R8i and up is similar.

Connection procedure

WARNING! Follow the instructions in chapter Safety instructions. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

Note: Before making the cable connections, check that the input of the auxiliary voltage transformer (T10) is selected correctly according to the supply voltage.

1. Open the door of the cabinet.

2. Remove any shrouds that protect the input busbars and cable entries.

3. Lead the cables into the inside of the cubicle. It is recommended to apply 360° grounding of the cable shields at the entry as shown below.

PE

L1

L2

L3

1)

Incoming cubicle

Notes:

1) Input power connection: L1, L2, L3 and PE. To be wired by the user. For selection of input power cables, see page 74.For the input power cable terminal sizes, tightening torques and cabinet lead-through sizes, see section Terminal and lead-through data for the input power cable on page 155.


94

4. Connect the cables as follows:

• Twist the cable shields into bundles and connect to cabinet PE (ground) busbar. Connect any separate ground conductors or cables to cabinet PE (ground) busbar.

• Connect the phase conductors to the input power terminals (L1, L2, L3). For the tightening torques, see page 155.

5. Provide support for the cables whenever necessary.

6. Refit all shrouds removed earlier and close the door.

Connecting the motor cable – units with no common motor terminals cubicle option +H359

Connection diagram – single inverter module feeds one motor

U2

V2

W2

PE

M3~U1

W1

V1

PE

Inverter module cubicle


95

Connection diagram – parallel inverter modules feed one motor

WARNING! The cabling from all inverter modules to the motor must be physically identical considering cable type, cross-sectional area, and length.

U2

V2

W2

PE

U2

V2

W2

M3~U1

W1

V1

PE


PE


U2

V2

W2

U2

V2

W2

M3~U1

W1

V1

PE


96



1. Disconnect the inverter cubicle from the DC supply (open the DC switch or remove the fuses). Ensure by measuring that the drive is dead.

2. Open the door of the inverter module cubicle: Unlock the handle, release it from the holder and turn upwards to release the door locking mechanism.

3. Remove the shroud that protects the output busbars and cable entries.

4. Remove the cooling fans. See Replacing the inverter module fans (2×R8i and up) on page 126.

5. Lead the cables into the inside of the cubicle. For minimum radio frequency interference and motor bearing current, ground the cable shield 360° at the lead-through.


- Cut the cables to suitable length. Strip the cables and conductors. Fasten the cable lugs to the conductor ends.

- Twist the cable shields into bundles and connect to cabinet ground busbar. - Connect the phase conductors to the output terminals. See the appropriate

connection diagram above.- Tighten the phase conductors and PE to 70 N·m (50 lbf·ft).

7. Refit the fans.

8. Refit the shroud removed earlier and close the door.

9. Connect the motor end of the cable (see the diagrams above). For minimum radio frequency interference and motor bearing current ground the cable shield 360° at the lead-through of the motor terminal box, or ground the cable by twisting the bare shield so that its width, when flattened, is at least 1/5 times its length (see the drawing below). For motor-specific instructions, see its documentation.


97

Inverter module cubicle from front, door closed

Inverter module cubicle from front, door open

Lower part of the inverter module cubicle from front, shroud removed

2

3

5

6

4 4

Terminals are behind the fan.

Grommet (in IP54 units only)

a b

b > 1/5 × a

Alternative 1:360° grounding of the shield

Conductive gasket

360° grounding of the cable shield at the inverter end

Alternative cable shield grounding means at the motor end

Alternative 2:grounding the twisted shield

9


98

Connecting the motor cable (units with the common motor cable connection terminals cubicle option +H359)

Connection diagram



1. Open the door of the common motor terminal cubicle: Unlock the handle, release it from the holder and turn upwards.

2. Remove the shrouds that protect the output busbars and cable entries.

3. Lead the cables into the cubicle. For minimum radio frequency interference and motor bearing current, ground the cable shield 360° at the lead-through.

U2

V2

W2

PE

M3~U1

W1

V1

PE

Inverter module cubicle Common motor terminal cubicle

Grommet (in IP54 units only)


99


- Cut the cables to suitable length. Strip the cables and conductors. Fasten the cable lugs to the conductor ends.

- Twist the cable shields into bundles and connect to cabinet PE (ground) busbar.

- Connect the phase conductors to the output terminals. See the Connection diagram above.

- Tighten the phase conductors and PE to 70 N·m (50 lbf·ft).

5. Refit the shrouds and close the door.

6. At the motor, connect the cables according to the Connection diagram above. For minimum radio frequency interference and motor bearing current ground the cable shield 360° at the lead-through of the motor terminal box, or ground the cable by twisting the shield as follows: flattened width > 1/5 × length. For the motor specific instructions, see the manufacturer’s user manual.

a b

b > 1/5 × a

Alternative 1:360° grounding of the shield

Conductive gasket

Alternative cable shield grounding means at the motor end

Alternative 2:grounding the twisted shield

6


100

Connecting external power supply for the auxiliary circuits

Frames R7i×R7i and R8i×R8i

As standard, the drive auxiliary circuit is supplied from the main power supply of the drive through an auxiliary voltage transformer. You do not need to connect any external auxiliary power supply for the auxiliary circuits.

If the drive is equipped with option +G307 (Terminals for connecting external control voltage), connect the external power supply as shown in the figure below. The circuit breaker Q200 is located in the Incoming cubicle of the drive. Maximum fuse: 16 A. For the current consumption of the the circuitry, see section Auxiliary circuit current consumption on page 164.

>

L N

Q200

321

PE

N

L

Power supply for control circuitry (units with option +G307 for UPS )

>


101

Frames 2×R8i and up

Standard unit without optional auxiliary control voltage transformer or terminals for connecting external control voltage

Connect the external auxiliary power supply for the cooling fans and control circuitry to breaker Q11. The breaker Q11 is located in the auxiliary control cubicle or in the inverter module cubicle. See section Auxiliary circuit current consumption on page 164 for the current consumption of the circuitry.

Units with optional auxiliary control voltage transformer and without terminals for connecting external control voltage (+G307)

Auxiliary power to drive cooling fans and control circuitry is supplied from the main power line through the optional auxiliary control voltage transformer (T10). No user connections are needed.

Power supply for fans and control circuitry (units without optional auxiliary control voltage transformer and without option +G307)

>

L N

Q11

321

PE

N

L

>


102

Units with terminals for connecting external control voltage (option +G307) and without optional auxiliary control voltage transformer

Connect the external auxiliary power supply for the drive control circuitry to breaker Q11. See section Auxiliary circuit current consumption on page 164 for the current consumption of the circuitry.

Connecting the control cables for the supply unit

The supply unit is controlled using the operating switch and optional reset and emergency stop buttons (option +G331) mounted on the cabinet door. No additional control connections are used or needed. However, it is also possible to

• halt the supply unit by an external emergency stop button (if the unit is equipped with a local emergency stop button, external buttons can be connected in series)

• read a fault indication through a relay output. Note concerning options +C139, +C140 and +C141: If relay output RO2 is used for on/off control of the optional liquid cooling unit, the fault indication is not in use. See page 45.

• communicate with the unit through a serial communication interface.

The standard I/O connections are presented under section Connections and use of the I/O in the supply unit, page 45. Refer to the circuit diagrams delivered with the drive for the connection terminals for the external control devices.

>

L N

Q11

321

PE

N

L

Power supply for control circuitry (units with option +G307 for UPS )

>


103

Connecting the control cables for the inverter unit

Default I/O connection diagramX2* RMIO

X20 X20

1 1 VREF- Reference voltage -10 V DC, 1 kohm < RL < 10 kohm2 2 AGND

X21 X21

1 1 VREF+ Reference voltage 10 V DC, 1 kohm < RL < 10 kohm2 2 AGND

3 3 AI1+ Speed reference 0(2)... 10 V, Rin > 200 kohm4 4 AI1-

5 5 AI2+ By default, not in use. 0(4)... 20 mA, Rin = 100 ohm6 6 AI2-

7 7 AI3+ By default, not in use. 0(4)... 20 mA, Rin = 100 ohm8 8 AI3-

9 9 AO1+ Motor speed 0(4)...20 mA 0...motor nom. speed, RL < 700 ohm10 10 AO1-

11 11 AO2+ Output current 0(4)...20 mA 0...motor nom. current, RL < 700 ohm12 12 AO2-

X22 X22

1 1 DI1 Stop/Start

2 2 DI2 Forward/Reverse 1)

3 3 DI3 Not in use

4 4 DI4 Acceleration & deceleration select 2)

5 5 DI5 Constant speed select 3)

6 6 DI6 Constant speed select 3)

7 7 +24VD +24 V DC max. 100 mA

8 8 +24VD

9 9 DGND1 Digital ground

10 10 DGND2 Digital ground

11 11 DIIL Start interlock (0 = stop) 4)

X23 X23

1 1 +24V Auxiliary voltage output and input, non-isolated, 24 V DC 250 mA 5)

2 2 GND

X25 X25

1 1 RO1 Relay output 1: ready

2 2 RO1

3 3 RO1

X26 X26

1 1 RO2 Relay output 2: running

2 2 RO2

3 3 RO2

X27 X27

1 1 RO3 Relay output 3: fault (-1)

2 2 RO3

3 3 RO3

=

=

Fault

A

rpm

* optional terminal block (not in all units)

1) Only effective if par. 10.03 is set to REQUEST by the user.

2) 0 = open, 1 = closed

3) See par. group 12 CONSTANT SPEEDS.

4) See parameter 21.09 START INTRL FUNC.

5) Total maximum current shared between this output and optional modules installed on the board.

DI4 Ramp times according to

0 parameters 22.02 and 22.03

1 parameters 22.04 and 22.05

DI5 DI6 Operation

0 0 Set speed through AI1

1 0 Constant speed 1



RMIO

Terminal block size:

cables 0.3 to 3.3 mm2 (22 to 12 AWG)

Tightening torque:

0.2 to 0.4 Nm

(0.2 to 0.3 lbf ft)


104

External control cable connections to the RMIO board for the ACS800 standard control program (Factory macro) are shown in the above diagram. For external control connections of other application macros, see the Standard Control Program Firmware Manual (3AFE64527592 [English]).


105



Open the cabinet door(s).

Remove any shrouds that limit access to the cable lead-throughs and cable trunking.

Run the cables into the inside of the cabinet through the grommets provided.

Top entry units only: If several cables need to be run through one grommet, use Loctite 5221 (cat. no. 25551) under the grommet to seal the cable entry.

Units with EMI conductive cushions only:

Run the cables between the cushions as shown below. Strip the cable at this location to enable proper connection of the bare shield and the cushions. Tighten the cushions firmly onto the cable shields.

If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).

On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the opening.

Strain relief EMI conductive cushions

Lead-through plate

Side view

Grommet

Cable shield Shielded twisted pair

Grounding wire

Copper foil

Stripped cable Conductive surface of the shield exposed

Stripped part covered with copper foil

Thinnest cableThickest cable

Top view


106

Connecting a PC

WARNING! Read and follow the instructions given in chapter Safety instructions. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

Connect PC to CH3 of RDCO board via a fiber optic link. RDCO is attached to an option slot of the RDCU unit. See also Fiber optic links below.

Installing optional modules

WARNING! Read and follow the instructions given in chapter Safety instructions. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

Insert optional modules (such as fieldbus adapters, I/O extension modules and pulse encoder interfaces) into the optional module slots of the RDCU unit and secure with two screws. The slots on the RDCU unit are described in Overview of power and control connections on page 42. See also the appropriate optional module manual for information on the cable connections.

Run the cables to the appropriate terminals. Wherever possible, use the existing cable trunking in the cabinet. Use sleeving wherever the cables are laid against sharp edges.

Note: When running cables to the swing-out frame, leave some slack in the cable at the hinge to allow the frame to open fully. Tie the cables to the cable supports wherever necessary.

Cut the cables to suitable length. Strip the cables and conductors.

Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block. Keep the unshielded portion of the cables as short as possible.

Connect the conductors to appropriate terminals. See page 98 for the location of the control unit and the circuit diagrams delivered with the unit.

Refit any shrouds removed earlier. Close the cabinet door(s).


107

Cabling of I/O and fieldbus modules

Cabling of pulse encoder interface module

Note 1: If the encoder is of unisolated type, ground the encoder cable at the drive end only. If the encoder is galvanically isolated from the motor shaft and the stator frame, ground the encoder cable shield at the drive and the encoder end.

Note 2: Twist the pair cable wires.

Fiber optic links

DDCS fiber optic links are provided by RDCO modules (optionally installed on the RDCU control units) for PC tools, master/follower link, NDIO, NTAC, NAIO, AIMA I/O module adapter and fieldbus adapter modules of type Nxxx. See the RDCO User’s Manual (3AFE 64492209 [English]) for the connections. Observe colour coding when installing fiber optic cables. Blue connectors go to blue terminals, and grey connectors to grey terminals.

When installing multiple modules on the same channel, connect them in a ring.

Shield

Module

2 3 41

Keep unshielded portion asshort as possible

To nearest PE terminal

2 3 41

65

43

21

65

43

21

87

0

8

4

C

2

6A

E1 3

5

79BD

F

CHASSIS

GND

NODE ID

SHLD

RTAC-01PULSE ENCODER INTERFACE

X2

X1

WD/INIT

CHB

CHA

SHLD

CHA+

CHA-

CHB+

CHB-

CHZ+

CHZ-

0 V

0 V

V OUT

+15V

V IN

+24V

Keep unshielded portion asshort as possible


108


109



This chapter contains an installation checklist.


Check the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person.

WARNING! Only qualified electricians are allowed to carry out the work described below. Follow the complete safety instructions of the drive. Ignoring the safety instructions can cause injury or death.

Open the main disconnector of the drive and lock it to open position.

Ensure by measuring that the drive is not powered.

Check that …

The drive cabinet has been fixed to floor, and if necessary (due to vibration etc.), also from top to the wall or roof.

The ambient operating conditions meet the specification in chapter Technical data.

If the drive will be connected to an IT (ungrounded) or a corner grounded TN supply network: The varistors and EMC filter of the drive (if any) have been disconnected. See chapter Electrical installation.

If the drive has been stored over one year: The electrolytic DC capacitors in the DC link of the drive have been reformed. See the separate reforming instructions (available in the Internet of from a local ABB representative).

There is an adequately sized protective ground conductor between the drive and the switchboard.

There is an adequately sized protective ground conductor between the motor and the drive.

All protective ground conductors have been connected to the appropriate terminals and the terminals have been tightened (pull conductors to check).

The supply voltage matches the nominal input voltage of the drive. Check the type designation label.

The input power cable has been connected to appropriate terminals, the phase order is right, and the terminals have been tightened (pull conductors to check).

The motor cable has been connected to appropriate terminals, the phase order is right, and the terminals have been tightened (pull conductors to check).

The brake resistors (present only with option +D151) has been connected to appropriate terminals, and the terminals have been tightened (pull conductors to check).

The voltage setting of the auxiliary voltage transformer T10 (if any) meet the supply voltage.


110

The motor cable (and brake resistor cable, if present) has been routed away from other cables.

No power factor compensation capacitors have been connected to the motor cable.

The control cables (if any) have been connected to the appropriate terminals on the inverter control board.

If a drive bypass connection will be used: The direct -on-line contactor of the motor and the drive output contactor are either mechanically or electrically interlocked (cannot be closed simultaneously).

There are no tools, foreign objects or dust from drilling inside the drive.

The cooling circuit joints at the shipping split joining cubicles are tight.

All bleed and drain valves have been closed.

All shrouds and cover of the motor connection box are in place. Cabinet doors have been closed.

The motor and the driven equipment are ready for start.

Check that …


111

Start-up


This chapter contains start-up instructions for the drive.

Start-up procedure

These instructions do not cover all start-up tasks of all possible variants of the drive, just the basic steps. Always refer to the delivery-specific circuit diagrams when proceeding with the start-up.

The designations in square brackets refer to the designations used in the circuit diagrams.

Action Additional information

Safety

WARNING! Only qualified electricians are allowed to commission the drive. Read and follow the safety instructions on the first pages of this manual. Neglecting the safety instructions can cause injury or death.

WARNING! Ensure that the disconnector of the supply transformer is locked to open position ie, no voltage is, or can be connected to the drive inadvertently. Check also by measuring that there is no voltage connected.

Checks with no voltage connected

Drive with main breaker (frame 2xRi+2xR8i and bigger units)

Check the current trip limits of the breaker preset at the factory.

General ruleEnsure the selectivity condition is fulfilled ie, the breaker trips at a lower current than the protection device of the supplying network, and that the limit is high enough not to cause unnecessary trips during the intermediate DC circuit load peak at start.

Long-term current limitAs a rule of thumb, this should be set to the rated input AC current of the drive.

Peak current limitAs a rule of thumb, this should be set to a value 3…4 times the rated input AC current of the drive.

Check the settings of the relays and breakers/switches of the auxiliary circuits.

Optional devices. See delivery specific circuit diagrams.

Disconnect any unfinished or unchecked 230/115 V AC cables that lead from the terminal blocks to the outside of the equipment.

Frame 2×R8i and up: Enable the memory backup battery on the PPCS branching units (APBU) by setting actuator 6 of switch S3 to ON. The branching units are located on the supply and inverter module cubicle swing-out frames.

By default, memory backup is switched off to save the battery.

Fill up and bleed the internal cooling circuit. Ensure that the coolant can flow freely in all cubicles. Start the cooling unit up.

Chapter Internal cooling circuit. For drives with the optional cooling unit (option codes +C140 or +C141), see ACS800-1007LC User’s Manual (3AFE68621101 [English]).

Start-up

112

Connecting voltage to the input terminals and auxiliary circuit

WARNING! Make sure that it is safe to apply voltage. Ensure that:

• nobody is working on the unit or circuits that are wired from outside into the cabinets

• covers of motor terminal boxes are in place.

Close the circuit breakers which connect the voltage to essential auxiliary devices, in other words: fans, boards, main breaker/contactor control circuit, emergency stop circuit, 24 V DC power supply.

To locate the circuit breakers, see the delivery-specific circuit diagrams and the cubicle designations on cabinet doors.

Close the cabinet doors.

Close the breaker of the supply transformer.

Drive with a grounding switch (option +F259): Open the grounding switch.

Drive with main contactor (frames R7i+R7i and R8i+R8i: Close the main switch disconnector (Q1).

Drive with main breaker (frame 2xRi+2xR8i and bigger units): Rack the withdrawable breaker in.

Closing the main contactor/breaker

Turn the operating switch to position S for two seconds and then back to position 1.

Checking the setting of the ground fault monitoring device Option +Q954. See IRDH275 Operating Manual by Bender (code: TGH1386) and the circuit diagrams delivered with the drive

Check the settings of the ground fault monitoring device.

Supply unit control program set-up

Parameters of the IGBT supply unit control program need not be set during the start-up procedure, or in normal use. In case the parameters need to be changed, switch the control panel to communicate with the supply unit as described in section Switching the control panel between the supply and inverter units on page 114. Alternatively, connect a PC equipped with a start-up and maintenance tool tool eg, DriveWindow, to channel CH3 of the inverter unit’s RDCU.

ACS800 IGBT Supply Control Program Firmware Manual (3AFE68315735 [English])

Inverter unit control program set-up

Follow the instructions in the inverter unit firmware manual to start up the inverter and set the parameters.

Firmware manual of the inverter unit

Units with sine filter (option +E206): Set parameter 95.04 EX/SIN REQUEST to SIN or EX&SIN.

Liquid cooling unit control program set-up

Units with optional liquid cooling unit (options +C139, +C140, +C141): Check that parameter 33.01 CONTROL TYPE is set to LOCAL CTRL in the liquid cooling unit control program.

Control panel of the liquid cooling unit must be in remote control mode Switch with the LOC/REM key of the panel. ACS800-1007LC Liquid-cooling Unit User's Manual (3AFE68621101)

Check that the pump starts when digital inputs DI5 (off/on) and DI6 (stop/start) are switched on.


Start-up

113

On-load checks

Check that the cooling fans rotate freely in the right direction, and the air flows upwards.

Check the rotation direction of the motor.

Check that the motor starts, stops and follows the speed reference when controlled with the control panel.

Check that the motor starts, stops and follows the speed reference when controlled through the customer-specific I/O or fieldbus.

Units with an emergency stop function (options +Q951, +Q952, +Q963 and +Q964): Test and validate the operation of the Emergency stop function.

See Wiring, start-up and operation instructions of safety options (+Q950, +Q951, +Q952, +Q963, +Q964, +Q967 and +Q968) for ACS800 cabinet-installed drives (3AUA0000026238 [English]) and the circuit diagrams delivered with the drive.

Units with cooling unit (options +C139, +C140, +C141): Make the on-load checks and adjustments of the cooling unit.

See ACS800-1007LC Liquid-cooling Unit User’s Manual (3AFE68621101 [English]).

Units with the Safe torque off function (option +Q968):

Test and validate the operation of the function.

See Wiring, start-up and operation instructions of safety options (+Q950, +Q951, +Q952, +Q963, +Q964, +Q967 and +Q968) for ACS800 cabinet-installed drives (3AUA0000026238 [English]) and the delivery-specific circuit diagrams.

Units with the Prevention of unexpected start function (option +Q950): Test the operation of the function.

See Wiring, start-up and operation instructions of safety options (+Q950, +Q951, +Q952, +Q963, +Q964, +Q967 and +Q968) for ACS800 cabinet-installed drives (3AUA0000026238 [English]) and the delivery-specific circuit diagrams.


Start-up

114

Switching the control panel between the supply and inverter units

The control panel is switched between the supply unit and inverter units as follows:

WARNING! The drive does not stop by pressing the control panel Stop key in remote control mode.

Changing control to the supply unit

Step Action Press… Display (example)

1. To enter the Drive Selection Mode

Note: In local control mode, the inverter unit trips if parameter 30.02 PANEL LOSS is set to FAULT. Refer to the appropriate application program firmware manual.

2. To scroll to ID number 2

3. To verify the change to the supply unit and display the warning or fault text

Changing control to the inverter unit

Step Action Press… Display (example)

1. To enter the Drive Section Mode

2. To scroll to ID number 1

3. To verify the change to the inverter unit

DRIVE

ACS 800 0490_3LM

ASXR7xxxID-NUMBER 1

ISU 800 0490_3LM

IXXR7xxxID-NUMBER 2

ACT ISU 800 0490_3LM

DC OVERVOLT (3210)

2 -> 380.0 V

*** FAULT ***

DRIVE

ISU 800 0490_3LM

IXXR7xxxID-NUMBER 2

ACS 800 0490_3LM

ASXR7xxxID-NUMBER 1

ACT FREQ 0.00 HzCURRENT 0.00 APOWER 0.00 %

1 L -> 0.0 rpm I

Start-up

115

ACS800-17LC-specific parameters in the IGBT Supply Control Program

The ACS800-17LC specific signals and parameters of IGBT Supply Control Program are described in the tables below.


Parameters

Term Definition

B Boolean

C Character string

Def. Default value

FbEq Fieldbus equivalent: the scaling between the value shown on the control panel and the integer used in serial communication

I Integer

R Real

T. Data type (see B, C, I, R)

No. Name/Value Description T./FbEq Def.

16 SYSTEM CTR INPUTS

Parameter lock, parameter back-up etc.

16.15 START MODE Selects the start mode. B LEVEL

LEVEL Starts the supply unit by the level of digital input DI2. The supply unit starts to modulate and the charging resistors will be by-passed when the supply unit RMIO board is powered, its digital input DI2 is ON and there are no faults.

0

EDGE Starts converter by EDGE of control command. Control command is selected by parameters 98.01 COMMAND SEL and 98.02 COMM. MODULE.

1

31 AUTOMATIC RESET

Automatic fault reset.

Automatic resets are possible only for certain fault types and when the automatic reset function is activated for that fault type.

The automatic reset function does not operate if the drive is in local control (L visible on the first row of the control panel display).

WARNING! If the start command is selected and it is ON, the supply unit may restart immediately after automatic fault reset. Ensure that the use of this feature will not

cause danger.

WARNING! Do not use these parameters when the drive is connected to a common DC bus. The charging resistors may be damaged in an automatic reset.

31.01 NUMBER OF TRIALS Defines the number of automatic fault resets the drive performs within the time defined by parameter 31.02.

I 0

0 … 5 Number of the automatic resets 0

31.02 TRIAL TIME Defines the time for the automatic fault reset function. See parameter 31.01.

R 30 s

1.0 … 180.0 s Allowed resetting time 100 … 18000

Start-up

116

Default values of parameters with the ACS800-17LC

When the IGBT Supply Control Program is loaded into the ACS800-17LC, the following parameters receive the default values given in the table below. Do not change the default values. If they are changed, the drive will not operate properly.

31.03 DELAY TIME Defines the time that the drive will wait after a fault before attempting an automatic reset. See parameter 31.01.

R 0 s

0.0 … 3.0 s Resetting delay 0 … 300

31.04 OVERCURRENT Activates/deactivates the automatic reset for the supply unit overcurrent fault.

B NO

NO Inactive 0

YES Active 65535

31.05 OVERVOLTAGE Activates/deactivates the automatic reset for the intermediate link overvoltage fault.

B NO

NO Inactive 0

YES Active 65535

31.06 UNDERVOLTAGE Activates/deactivates the automatic reset for the intermediate link undervoltage fault.

B NO

NO Inactive 0

YES Active 65535

Parameter Default value

11.01 DC REF SELECT FIELDBUS

11.02 Q REF SELECT PARAM 24.02

70.01 CH0 NODE ADDR 120

70.19 CH0 HW CONNECTION RING

70.20 CH3 HW CONNECTION RING

71.01 CH0 DRIVEBUS MODE NO

98.01 COMMAND SEL MCW

98.02 COMM. MODULE INU COM LIM

201.09 PANEL DRIVE ID 2

202.01 LOCAL LOCK TRUE

No. Name/Value Description T./FbEq Def.

Start-up

117

ACS800-17LC-specific parameters in the application program

The ACS800-17LC specific actual signals and parameters in the ACS800 Standard Control Program (running on the inverter control board) are described below.


Actual signals and parameters of supply unit in inverter unit program

Term Definition

Actual signal Signal measured or calculated by the drive. Can be monitored by the user. No user setting possible.

FbEq Fieldbus equivalent: The scaling between the value shown on the control panel and the integer used in serial communication.

Parameter A user-adjustable operation instruction of the drive

No. Name/Value Description FbEq Def.

09 ACTUAL SIGNALS Signals from the supply unit (line-side converter).

09.12 LCU ACT SIGNAL 1 Line-side converter signal selected by par. 95.08 LCU PAR1 SEL.

1 = 1 106

09.13 LCU ACT SIGNAL 2 Line-side converter signal selected by par. 95.09 LCU PAR2 SEL.

1 = 1 110

Start-up

118

95 HARDWARE SPECIF Line-side converter references and actual signal selections.

95.06 LCU Q PW REF Reactive power reference for the line-side converter i.e. the value for par. 24.02 Q POWER REF2 in the IGBT Supply Control Program.

Scaling example 1: 10000 equals to a value of 10000 of parameter 24.02 Q POWER REF2 and 100% of par. 24.01 Q POWER REF (i.e. 100% of the converter nominal power given in par. 04.06 CONV NOM POWER) when par. 24.03 Q POWER REF2 SEL is set to PERCENT.

Scaling example 2: Par. 24.03 Q POWER REF2 SEL is set to kVAr. A value of 1000 of par. 95.06 equals to 1000 kVAr of par. 24.02 Q POWER REF2. Value of par. 24.01 Q POWER REF is then 100 (1000 kVAr divided by converter nominal power in kVAr)%.

Scaling example 3: Par. 24.03 Q POWER REF2 SEL is set to PHI. A value of 10000 of par. 95.06 equals to a value of 100 deg of parameter 24.02 Q POWER REF2 which is limited to 30 deg. The value of par. 24.01 Q POWER REF will be determined approximately according to the following equation where P is read from actual signal 1.09 POWER:

0

-10000 ... +10000 Setting range. 1 = 1

95.07 LCU DC REF DC voltage reference for line converter i.e. the value for parameter 23.01 DC VOLT REF.

0

0 … 1100 Setting range in volts. 1 = 1 V

95.08 LCU PAR1 SEL Selects the line converter address from which actual signal 9.12 LCU ACT SIGNAL 1 is read.

106

0 … 10000 Parameter index 1 = 1

95.09 LCU PAR2 SEL Selects the line converter address from which actual signal 9.13 LCU ACT SIGNAL 2 is read.

110

0 … 10000 Parameter index 1 = 1

No. Name/Value Description FbEq Def.

30cos PS--- P

P2 Q2+-----------------------==

30 deg

SQ

PPositive reference 30 deg denotes capacitive load.

Negative reference 30 deg denotes inductive load.

-10000 +100000

30 (deg)

3000-3000

10

1000-1000

-10-30 0

Par. 95.01

Par. 24.02

Start-up

119

Fault tracing

LEDs

Warning and fault messages

The control panel will display the warnings and faults of the unit (supply or inverter unit) that the panel is currently monitoring.

Information on warnings and faults concerning the supply unit are contained within the IGBT Supply Control Program Firmware Manual (3AFE68315735 [English]).

The warnings and faults concerning the inverter unit vary depending on the delivery. For them, refer to the inverter control program firmware manual delivered with the drive.

Warning/Fault message from the unit not being monitored by the control panel

Flashing messages WARNING, ID:2 or FAULT, ID:2 on the control panel display indicate a warning or fault state in the supply unit when the panel is controlling the inverter unit, for example:

To display the warning or fault identification text, switch the control panel to view the supply unit as described in section Switching the control panel between the supply and inverter units on page 114.

Conflicting ID numbers

The ID numbers of the supply unit and inverter unit are defined at the factory. Do not change the settings. If you change the ID numbers equal by accident, the panel stops communicating with either of the units. Correct the settings as follows:

Location LED Indication

RMIO board (RDCU drive control unit)

Red Fault state.

Green The power supply on the board is OK.

Control panel mounting platform (with the control panel removed)

Red Fault state.

Green The main +24 V power supply for the control panel and the RMIO board is OK.

AINT board (visible through the transparent cover on the front of the supply and inverter modules

V204 (green) +5 V voltage of the board is OK.

V309 (red) Prevention of unexpected start or Safe torque off is ON.

V310 (green) IGBT control signal transmission to the gate driver control boards is enabled.

FAULT, ID:2ACS 800 0490_3MR*** FAULT ***LINE CONV (FF51)

Fault tracing

120

• Disconnect the panel cable from the RMIO board of the inverter unit.

• Set the ID number of the supply unit RMIO board to 2. For the setting procedure, see the inverter control program firmware manual.

• Connect the disconnected cable to the RMIO board of the inverter unit again and set the ID number to 1.

Fault tracing

121

Maintenance


This chapter contains preventive maintenance instructions.

Maintenance intervals

If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB.

Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to http://www.abb.com/drives.

Note: If the drive is equipped with the cooling unit (options +C139, +C140 or +C141), see also the maintenance intervals given in ACS800-1007LC User’s Manual (3AFE68621101 [English]).

Fans

Replacing the cooling fan of converter module (frames R7i and R8i)

Replace the fan as described under Replacing the cooling fans in supply module cubicle, page 125.

Interval Maintenance action Instruction

Every year Drives with IP54 degree of protection: door filter check and replacement if dirty

-

Every year of storage Capacitor reforming See Capacitor Reforming Instructions (3BFE64059629 [English]).

Every 3 years Checking and cleaning of the diode supply and inverter module quick connectors

-

Every 6 years Cabinet cooling fan change

See section Fans.

Power module cooling fan change

Every 9 years Capacitor change Contact ABB.

Every 10 years Memory backup battery renewal of PPCS branching unit (APBU-xx)

See section Replacing the PPCS branching unit (APBU-xx) memory backup battery on page 135.

Maintenance

http://www.abb.com/drives

122

Replacing the additional fan in the incoming cubicle (frames R7i+R7i and R8i+R8i)


1. Disconnect the drive from the power line.

2. Open the incoming cubicle door.

3. Remove the four mounting screws of the fan.

4. Disconnect the fan power cable.

5. Pull out the fan.

6. Install new fan in reverse order.

5

3

4

Maintenance

123

Replacing the auxiliary control cubicle fan (frames 2×R8i+2×R8i and up)



2. Open the auxiliary control cubicle door.

3. Loosen the two screws that fasten the fan mounting plate.

4. Disconnect the fan power cable.

5. Pull out the fan together with its mounting plate.

6. Undo the four screws that fasten the fan to its mounting plate.


5

3

6

Maintenance

124

Replacing the fan in the incoming cubicle (frames 2×R8i+2×R8i and up)



2. Open the door and remove the shroud to gain access to the fan.

3. Remove the four mounting screws (and the four nuts in 1000 mm cubicle) of the fan.

4. Disconnect the power supply cable of the fan and pull the fan out of the cubicle.

5. Remove the four screws (and the four nuts in 1000 mm cubicle) that fasten the fan and the fan grille.

6. Install a new fan in reverse order.

1000 mm wide cubicle

3

5

35

22

600 mm wide cubicle

Maintenance

125

Replacing the cooling fans in supply module cubicle



2. Open the door and remove the lower shroud of the cubicle.

3. Unplug the fan power supply.

4. Lift the back part of the fan up a bit and remove the two screws that fasten the collar to the cubicle. Pull the collar out of the cubicle.

5. Remove the four screws that fasten the fan to the collar.

6. Install a new fan in reverse order.

4

5

Maintenance

126

Replacing the inverter module fans (2×R8i and up)



2. Open the inverter cubicle door and remove the shroud to gain access to the fan.

3. Disconnect the fan wiring plug.

4. Remove the two locking screws.

5. Pull the fan (together with its collar) out along its sliding rails.

6. Remove the two screws that fasten the fan to the support bracket at front.

7. Remove the four screws that fasten the fan to its collar.


Replacing the additional fan in the common motor terminals cubicle

Replace the fan in the same way as described under Replacing the auxiliary control cubicle fan (frames 2×R8i+2×R8i and up) on page 123.

5

4

6

7

Maintenance

127

Reduced run capability

The reduced run capability is available for units with parallel-connected inverter modules of frame sizes 2×R8i and up, and for parallel-connected IGBT supply modules of frame sizes 4×R8i and up. If one of the parallel-connected inverter or supply modules fails, the unit can continue to be run at reduced power using the remaining modules.

Maintenance

128

Replacing supply and inverter modules

Note: Performing this action requires the following accessories that are not included with the drive as standard:• Winch (order code: 68847826)• Installation stand (order code: 68847711).


WARNING! When re-attaching coolant hoses, do not overtighten the outer nuts of the unions – leave 2 to 3 mm of thread visible. Overtightening will break the hose.


2. Open the module cubicle door and remove the shroud to gain access to the fan.

3. Close the inlet (a) and outlet (b) valves of the cubicle, and drain the cooling circuit (see Draining the internal cooling circuit on page 140. Note: Drain (d) and bleed (c) valves have locking handles. Release the mechanism before turning.

4. Fasten the right-hand side support of the winch to the support frame of the cubicle (four bolts). Fasten the left-hand side support of the winch to the support frame of the cubicle (four bolts). Note: Position the guide pins of the supports in the holes of the cabinet frame before tightening the bolts. For detailed instructions see Installing the winch on page 132.

5. Install the winch: Lead the crossbeam through the left and right winch support and the winch body. Lock the crossbeam with two locking pins (a).

6. Open the swing-out frame: two screws on the left-hand side, two on the right.

7. Open the locking of the auxiliary hinge of the swing out frame to allow the frame to open fully: one screw on top (a), one on bottom (b).

8. Decouple the cooling circuit inlet pipe from the module: Unscrew the locking nut until fully open and pull the pipe out.

9. Decouple the cooling circuit outlet pipe from the module: Unscrew the locking nut until fully open and pull the pipe out.

2 mm

Maintenance

129

b

a

c

d

2 Removing the shrouds 3 Draining the cooling unit 4 Fastening the supports of the winch

5 Installing the winch

6 Opening the swing-out frame

7 Opening the locking 8 Decoupling the inlet (8) and outlet (9)9

9

8

a

b

aa

Maintenance

130

10. Unplug the fiber optic cable from the module.

11. Unplug the terminal block from the module.

12. Remove the module mounting screws (four at top, two at bottom).

13. Disconnect the DC output busbars from the module. Beware not to drop the screws inside the module!

14. Assemble the module installation stand. See Installing the installation stand on page 133. Pay attention to the width: Select the right braces to match the width of the stand to the width of the cubicle.

15. Fasten the module installation stand to the frame of the cubicle (2 × 5 screws). Align the stand and the rails on which the module lies on in the cubicle. Adjust the height of the feet. Note: Remove the cabinet hinge first if necessary.

WARNING! The feet must lean on a solid floor. The cubicle may topple over when the heavy module is pulled out if the stand is not supported properly.

16. Fasten the lifting bar of the winch to the two module lifting holes.

WARNING! Before fastening the lifting bar, always ensure that the lifting cable is tightly wound on the drum of the winch. A slack cable may slip, making the lifting of a heavy module unstable. A swinging or falling module may cause damage, injury or even death. See section Use of the hand-operated winch (page 18) for more detailed information on safe use of the winch.

17. Pull the module out of cubicle onto the installation stand. Keep the pipes and wires away from the sharp edges.

18. Winch the module up.

19. Remove the module installation stand.

20. Winch the module down and lay it on a pallet.

WARNING! The module is heavy and its centre of gravity is high. The module topples over easily. Never manoeuvre it in upright position untied. It is highly recommended to lay the module on its side before moving the pallet.

21. Move the pallet with the module aside.

22. Before installing a new module, check and service the quick connector through which the AC output busbars or the cubicle connect to the module:

• Check the tightness of the motor cable connections at the quick connector: 70 N·m (52 lbf·ft).

• Clean all contact surfaces of the quick connector and apply a layer of suitable joint compound eg, Isoflex® Topas NB 52 from Klüber Lubrication, onto them.

23. Install new module in reverse order.

Maintenance

131

10 Unplugging the fiber optic cables

11 Unplugging the terminal block

12 Removing the mounting screws

16 Fastening the lifting bar

18 Winching the module up

19 Removing the installation stand

13 Disconnecting the DC busbars

11

10

1212

12

12

1212

14 Fastening the installation stand

15 Pulling the module out

20 Winching the module down

Maintenance

132

Installing the winch

The winch is available from ABB as an accessory. The order code is 68847826.

1. Fasten the right-hand side support of the winch to the support frame of the cubicle (four screws). Fasten the left-hand side support of the winch to the support frame of the cubicle (four screws). Note: Position the guide pins of the supports in the holes of the cabinet frame before tightening the screws.

2. Lead the beam (a) through the left and right winch support and the winch body. Lock the beam with two locking pins (b).

WARNING! Before fastening the lifting bar to the module, always ensure that the lifting cable is tightly wound on the drum of the winch. A slack cable may slip, making the lifting of a heavy module unstable. A swinging or falling module may cause damage, injury or even death. See page 18 for detailed information on safe use of the winch.

2

b

1

a

b

Do not overtighten! Max.torque 5.5 N·m (4 lbf·ft). Ensure that the studs are inserted into frame holes when tightening the screws.

Maintenance

133

Installing the installation stand

An installation stand for supply and inverter module replacement is available from ABB as an accessory. The order code is 68847711.

1. Fasten the module installation stand to the frame of the cubicle (2 × 5 screws). Align the stand and the rails in the cubicle on which the module lies. Adjust the height of the feet. Note: Remove the cabinet hinge first if necessary.

WARNING! The feet must lean on a solid floor. The cubicle may topple over when the heavy module is pulled out if the stand is not supported properly.

Do not overtighten (max. torque 5.5 N·m [4 lbf·ft]). Ensure that the guide studs are in frame holes before tightening screws.

Fixing of triangular support

Brace

Fixing of braces

Slide plane and support feet

Hooks at this end of plate have to enter holes in frame cabinet.

With these threads it is possible to fix the unit to the slide plate.

Do not use more than one slide plate at a time.

These hooks must enter holes in the brace.

Maintenance

134

Capacitors

The converter modules employ several electrolytic capacitors. Their lifespan depends on the operating time of the drive, loading and ambient temperature. Capacitor life can be prolonged by lowering the ambient temperature.

It is not possible to predict capacitor failure. Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected.

Reforming the capacitors

Reform (re-age) spare part capacitors once a year according to Capacitor reforming instructions (64059629 [English], available through your local ABB representative.

Replacing the capacitors

Contact an ABB service representative.

Control panel

Cleaning the control panel

Clean the control panel with a damp cloth. Do not use solvents or abrasives.

Maintenance

135

Replacing the PPCS branching unit (APBU-xx) memory backup battery

1. Switch off the power to the unit.

2. Open the screws on the cover (3 pcs).

3. Slide off the cover.

4. Remove the battery.

5. Insert the new CR 2032 battery and reattach the cover.

2 3 4

Maintenance

136

Maintenance

137


General

The cooling system of the drive consists of two circuits: firstly, the internal cooling circuit that covers the heat-generating electrical components and transfers the heat to the cooling unit, and the external cooling circuit that is usually part of a larger external cooling system. This chapter deals with the internal cooling circuit.

Internal cooling system diagram

The following is a diagram of how the coolant circulates in the supply, inverter and brake units of a drive system.

The modules in each cubicle can be isolated from the main cooling circuit by closing the inlet (a) and outlet valves (b). Each cubicle is also equipped with a drain valve (c) and a bleed valve (d).

Supply module

A/L

LCL filter Inverter modules Brake chopper

b d

a c a c a c a c

b d b d b d CoolantOUT

CoolantIN

A/L = Air to liquid heat exchanger

A/L A/L A/LA/LA/L A/L


138

Connection to a cooling unit

Connection to an ACS800-1007LC cooling unit

Refer to the ACS800-1007LC Cooling Unit User’s Manual (3AFE68621101, English).

Connection to a custom cooling unit

General requirements

Equip the system with an expansion tank to damp pressure rise due to volume changes when the temperature varies. Keep the pressure within the limits specified in Specifications below. Install a pressure regulator to ensure that the maximum permissible operating pressure is not exceeded.

Install a bleed valve at the highest point of the cooling circuit.

The materials used in the cooling system are listed in Specifications on page 141.

Coolant temperature control

The temperature of the coolant in the internal cooling circuit must be kept within the limits specified in Specifications on page 141. Note that the minimum temperature is dependent on ambient temperature and relative humidity.

The following diagram shows an example of coolant temperature control using the three-way valve in the external cooling circuit. Part of the infeed coolant flow is directed into the return pipe through a three-way valve without letting it circulate in heat exchanger if the coolant in the internal circuit is too cold.

Installation

Lay liquid piping with extreme care. Secure the pipes properly mechanically and check for leaks.

Infeed

Bypass valve

TC

Return

External circuitInternal circuit

Heat exchanger


139

Filling up and bleeding the internal cooling circuit

Both the drive and coolant must be at room temperature before filling in the cooling circuit.

WARNING! Ensure that the maximum permissible operating pressure is not exceeded. When necessary regulate the pressure to appropriate level by draining excess coolant out of the system.

WARNING! Bleeding of the cooling circuit is very important and has to be done with great care. Air bubbles in the cooling circuit may reduce or completely block coolant flow and lead to overheating. Let the air out of the cooling system while filling in coolant and, e.g. after any power module replacements.

Drive line-ups with an ACS800-1007LC cooling unit

Follow the filling up and bleeding instructions in ACS800-1007LC Cooling Unit User’s Manual (3AFE68621101 [English]).

Drive line-ups with a custom cooling unit

Notes:

• The bleed valves in the line-up are used only to vent the air from the circuit so that it can be displaced by the coolant. The actual bleeding of the circuit must be done via an external bleed valve installed at the highest point of the cooling circuit. The most practical location for the valve is usually near or at the cooling unit.

• Observe the instructions given by the manufacturer of the cooling unit. Pay special attention to filling up and bleeding the pumps properly as they may be damaged if operated when dry.

• Draining propylene glycol into the sewer system is not allowed.

1. Open the bleed valve at the cooling unit.

2. Open the inlet, outlet and bleed valves of one drive cubicle.

3. Lead the bleed hoses into buckets or other suitable containers. Extend the standard hoses if necessary.

4. Fill the circuit with coolant. For coolant specification, see below.

5. After the drive unit is filled up, coolant will start flowing from the bleed hose of the drive cubicle. Let some coolant flow out before closing the bleed valve.

6. Close the inlet, outlet and bleed valves of the drive cubicle.

7. Repeat steps 2…6 for all drive cubicles in the line-up.

8. Open the inlet and outlet valves in all drive cubicles. Let any air remaining in the system out through the bleed valve at the cooling unit.

9. Close the bleed valve at the cooling unit.


140

10. Continue to fill in coolant until a base pressure of 100…150 kPa is achieved.

11. Open the bleed valve of the pump to allow any air out.

12. Re-check the pressure and add coolant if necessary.

13. Start the coolant pump. Let any air remaining in the system out through the bleed valve at the cooling unit.

14. After one to two minutes, stop the pump or block the coolant flow with a valve.

15. Re-check the pressure and add coolant if necessary.

16. Repeat steps 13 to 15 a few times until all air is let out of the cooling circuit. Listen for a humming sound and/or feel the piping for vibration to find out if there is still air left in the circuit.

Draining the internal cooling circuit

The internal cooling circuit can be drained through the drain valves in each cubicle. The power modules in any cubicle can be drained without draining the whole internal cooling circuit.

WARNING! High-pressure warm coolant may be present in the internal cooling circuit. No work on the cooling circuit is allowed until the pressure is lowered down by stopping the pumps and draining coolant.

1. Lead the bleed and drain hoses to buckets or other suitable containers. Extend the standard hoses if necessary.

Note: Draining propylene glycol into the sewer system is not allowed.

2. Open the bleed valves to let air displace the liquid.

3. If required, dry the piping with compressed oil-free air of less than 6 bar.

4. If the drive is to be stored in temperatures below 0 °C (32 °F),• dry the cooling circuit with air• fill the cooling circuit with a mixture of water, corrosion inhibitor and DOW Propylene Glycol according to Freeze protection and corrosion inhibition below.• drain the cooling circuit again.

Adding inhibitor

Add inhibitor in the internal circuit every second year. The amount to be added is 0.5% of the total coolant quantity in the circuit. Use e.g. Cortec VpCI-649 (by Cortec Corporation, www.cortecvci.com).


141

Specifications

Temperature limits

Ambient temperature: See chapter Technical data.

Minimum coolant inlet temperature: Condensation is not allowed. The minimum coolant temperature to avoid condensation (at an atmospheric pressure of 1 bar) is shown below as a function of the relative humidity (φ) and the ambient temperature (Tair).

Maximum coolant inlet temperature for the drive

Drive with the optional liquid cooling unit (+C140 or +C141):

• 38 °C when the drive output capacity is not derated• 38 °C … 45 °C when the drive output capacity is derated by 1% per 1 °C

temperature increase.

Drive without the optional liquid cooling unit:

• 42 °C when the drive output capacity is not derated• 42 °C … 48 °C when the drive output capacity is derated by 1% per 1 °C

temperature increase.

Maximum inlet temperature variation: ±4°C

Maximum temperature rise: 13 °C; depends on mass flow.

Pressure limits

Base pressure: 100…150 kPa (recommended); 200 kPa (maximum). “Base pressure” denotes the pressure of the system compared with the atmospheric pressure when the cooling circuit is filled with coolant.

Tair

(°C)

Min. Tcoolant (°C)

φ = 95% φ = 80% φ = 65% φ = 50% φ = 40%

5 4.3 1.9 -0.9 -4.5 -7.4

10 9.2 6.7 3.7 -0.1 -3.0

15 14.2 11.5 8.4 4.6 1.5

20 19.2 16.5 13.2 9.4 6.0

25 24.1 21.4 17.9 13.8 10.5

30 29.1 26.2 22.7 18.4 15.0

35 34.1 31.1 27.4 23.0 19.4

40 39.0 35.9 32.2 27.6 23.8

45 44.0 40.8 36.8 32.1 28.2

50 49.0 45.6 41.6 36.7 32.8

55 53.9 50.4 46.3 42.2 37.1

Not allowed as standard but the coolant temperature must be 5 °C or above. Consult an ABB representative if operation below coolant temperature 5 °C is required.

Example: At an air temperature of 45 °C and relative humidity of 65% the coolant temperature may not be below +36.8 °C


142

Air counterpressure in the expansion tank: 40 kPa

Maximum design pressure: 600 kPa

Minimum pressure difference: 100 kPa / 120 kPa (hydrostatic)

Maximum pressure difference: 250 kPa

Water quality

Freeze protection and corrosion inhibition

A water-glycol solution is allowed for freeze protection. The glycol must be pure Dow Propylene Glycol (CAS Number: 57-55-6, available from The Dow Chemical Company, www.dow.com).

Add inhibitor to the coolant every second year. The amount to be added is 0.5% of the total coolant quantity in the circuit. Use, for example, Cortec VCI-649 (by Cortec Corporation, www.cortecvci.com).

Glycol concentration

The graph below shows the required glycol concentration in weight percentage according to ambient/storage temperature T.

Tap waterThe use of tap water is allowed as follows. Tap water must fulfil the requirements of the Council Directive 98/83/EC of 3/11/98 on the quality of water intended for human consumption. Corrosion inhibition with 0.5% by volume Cortec VCI-649 is required.

pH value 6…9

Chloride < 50 mg/l

Sulphate < 100 mg/l

Total dissolved solids < 200 mg/l, no deposits are allowed at the temperature of +57 °C

Total hardness as CaCO3 < 250 mg/l

Conductivity < 400 µS/cm (this equals the resistance of > 2500 ohm/cm)

The water must be clean of solid matter.

0

20

40

60

80

-50 -40 -30 -10 0-20T (°C)

+5

Glycol concentration% (weight)


http://www.dow.com

http://www.cortecvci.com

143

WARNING! Operation at temperatures below 0 °C (32 °F) is not permitted even with antifreeze.

Note: If more than 25% or DOW Propylene Glycol is added, the pressure loss in the system increases. An operating pressure of more than 150 kPa is required for sufficient flow.

Materials

Materials used in the internal cooling circuit are listed below. Note: These are also the only materials that can be used in the external cooling circuit.

• stainless steel AISI 316L (UNS 31603)• heavy gauge aluminium• plastic materials such as PA, PEX and PTFE

Note: PVC hoses are not suitable for use with antifreeze.• rubber gasketing NBR (nitrile rubber).

WARNING! If connecting external piping to the internal cooling circuit, use only materials that are specified above. Copper and brass must not be used under any circumstances. Even minor dissolution of copper can cause copper precipitation on aluminium and subsequent galvanic corrosion. The liquid cooling system may not contain any zinc eg, galvanized pipes, at all since zinc would react with the inhibitor.

If the plant incorporates normal iron pipes or cast iron accessories eg, motor housings, a liquid cooling unit with a heat exchanger (such as the ACS800-1007LC) must be used to separate the systems.


144


145

Technical data


This chapter contains the technical specifications of the drive eg, ratings, frame sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings, and warranty information.

Ratings

The rating for the drive with a 50 Hz supply are given below. The symbols are defined below the table.

Drive type Nominal ratings No-overload use

Light-overload use Heavy-duty use

Icont.max Imax Pcontmax I2N PN I2hd Phd

A (AC) A kW A kW A kW

UN = 400 V

ACS800-17LC-0110-3 159 251 90 153 90 119 55

ACS800-17LC-0140-3 205 251 110 197 110 153 75

ACS800-17LC-0170-3 240 335 132 230 132 180 90

ACS800-17LC-0200-3 295 437 160 283 160 221 132

ACS800-17LC-0260-3 377 512 200 362 200 282 160

ACS800-17LC-0350-3 500 674 250 480 250 374 200

ACS800-17LC-0430-3 625 837 355 600 355 468 250

ACS800-17LC-0580-3 835 1037 500 802 450 625 355

ACS800-17LC-0870-3 1250 1590 710 1200 710 935 500

ACS800-17LC-1130-3 1635 1994 900 1570 900 1223 710

ACS800-17LC-1680-3 2430 2941 1400 2333 1400 1818 1000

ACS800-17LC-2220-3 3210 3906 1800 3082 1800 2401 1400

ACS800-17LC-3300-3 4765 5799 2800 4574 2400 3564 2000

UN = 500 V

ACS800-17LC-0120-5 139 232 90 133 75 104 55

ACS800-17LC-0170-5 191 252 132 183 110 143 90

ACS800-17LC-0210-5 238 335 160 228 160 178 110

ACS800-17LC-0250-5 290 430 200 278 160 217 132

ACS800-17LC-0310-5 355 515 200 341 200 266 160

ACS800-17LC-0410-5 475 673 315 456 315 355 200

ACS800-17LC-0520-5 595 838 400 571 400 445 315

ACS800-17LC-0690-5 795 1042 560 763 500 595 400

ACS800-17LC-1030-5 1190 1589 800 1142 800 890 630

ACS800-17LC-1350-5 1560 1996 1000 1498 1000 1167 800

ACS800-17LC-2000-5 2310 2943 1600 2218 1600 1728 1200

ACS800-17LC-2640-5 3050 3885 2000 2928 2000 2281 1600

ACS800-17LC-3930-5 4540 5801 3200 4358 3200 3396 2800

Technical data

146

Definitions

Derating

The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres (3281 ft), or if the ambient temperature exceeds +45 °C (+113 °F).

Temperature derating

In the temperature range +45 °C (+113 °F) to +55 °C (+131 °F), the rated output current is decreased by 0.5% for every additional 1 °C (1.8 °F). The output current is calculated by multiplying the current given in the rating table by the derating factor.

Example If the ambient temperature is 55 °C (+131 °F), the derating factor is 100% - 0.5 · 10 °C = 95% or 0.95. The output current is then 0.95 × I2N or 0.95 × Icont.max.

UN = 690 V

ACS800-17LC-0130-7 106 137 110 102 90 79 75

ACS800-17LC-0170-7 139 206 132 133 132 104 90

ACS800-17LC-0210-7 179 265 200 172 160 134 132

ACS800-17LC-0280-7 237 386 250 228 200 177 160

ACS800-17LC-0390-7 330 604 315 317 315 247 250

ACS800-17LC-0470-7 395 604 400 379 355 295 250

ACS800-17LC-0630-7 530 872 560 509 500 396 400

ACS800-17LC-0950-7 795 1344 800 763 710 595 630

ACS800-17LC-1240-7 1040 1710 1000 998 1000 778 800

ACS800-17LC-1840-7 1540 2538 1600 1478 1400 1152 1200

ACS800-17LC-2430-7 2035 3350 2000 1954 2000 1522 1600

ACS800-17LC-3620-7 3025 4974 3200 2904 2800 2263 2400

ACS800-17LC-4630-7 3878 5802 4000 3723 3600 2901 2800

ACS800-17LC-5300-7 4432 6630 4400 4255 4000 3315 3200

ACS800-17LC-5960-7 4986 7460 5200 4787 4800 3730 3600PDM 00430970

Nominal ratings

Icont.max Continuous rms output current. No overloadability at 45 °C (113 °F).

Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed by drive temperature.

Typical ratings for no-overload use

Pcont.max Typical motor power. The power ratings apply to most IEC 60034 motors at nominal voltage (400, 500 or 690 V).

Typical ratings for light-overload use (10% overloadability)

I2N Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.

PN Typical motor power. The power ratings apply to most IEC 60034 motors at nominal voltage (400, 500 or 690 V).

Typical ratings for heavy-duty use (50% overloadability)

I2hd Continuous rms current. 50% overload is allowed for 1 minute every 5 minutes.

Phd Typical motor power. The power ratings apply to most IEC 60034 motors at nominal voltage (400, 500 or 690 V).

Drive type Nominal ratings No-overload use

Light-overload use Heavy-duty use

Icont.max Imax Pcontmax I2N PN I2hd Phd

A (AC) A kW A kW A kW

%°C

Technical data

147

Altitude derating

At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 1% for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool. If the installation site is higher than 2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further information.

Type equivalence table

Drive type Frame sizes

(supply + inverter)

Supply modules Inverter modules

Qty Type Qty Type

UN = 400 V

ACS800-17LC-0110-3 R7i+R7i 1 ACS800-104LC-0120-3 1 ACS800-104LC-0120-3




ACS800-17LC-0260-3 R8i+R8i 1 ACS800-104LC-0310-3+E205 1 ACS800-104LC-0310-3+E205




ACS800-17LC-0870-3 2×R8i+2×R8i 2 ACS800-104LC-0470-3+E205 2 ACS800-104LC-0470-3+E205





UN = 500 V














UN = 690 V








Technical data

148

1-phase brake choppers (option +D150) and resistors (option +D151)

3-phase brake units (option +D152)









PDM 00430970

Drive type Brake chopper type Brake resistors

Type In (rms) Resistor

A Ohm

UN = 690 V

ACS800-17LC-0130-7 NBRW-669C SAFUR200F500 107 2.72






ACS800-17LC-0630-7 2xNBRW-669C 2xSAFUR200F500 214 1.36

ACS800-17LC-0950-7 - - - -

ACS800-17LC-1240-7 - - - -

ACS800-17LC-1840-7 - - - -

ACS800-17LC-2430-7 - - - -

ACS800-17LC-3620-7 - - - -

ACS800-17LC-4630-7 - - - -

ACS800-17LC-5300-7 - - - -

ACS800-17LC-5960-7 - - - -

Drive type Brake unit type IDC (rms) Resistor Cubicle width *

A Ohm mm

UN = 400 V

ACS800-17LC-0110-3 ACS800-607LC-0250-3 155 3×3.5 400/700

ACS800-17LC-0140-3 ACS800-607LC-0250-3 155 3×3.5 400/700

ACS800-17LC-0170-3 ACS800-607LC-0250-3 155 3×3.5 400/700

ACS800-17LC-0200-3 ACS800-607LC-0250-3 155 3×3.5 400/700

ACS800-17LC-0260-3 ACS800-607LC-0250-3 155 3×3.5 400/700

ACS800-17LC-0350-3 ACS800-607LC-0250-3 155 3×3.5 400/700

ACS800-17LC-0430-3 ACS800-607LC-0500-3 310 3×1.7 400/700

Drive type Frame sizes

(supply + inverter)

Supply modules Inverter modules

Qty Type Qty Type

Technical data

149

* first value for units wirh bottom exit and second for units with top exit

ACS800-17LC-0580-3 ACS800-607LC-0500-3 310 3×1.7 400/700

ACS800-17LC-0870-3 - - - -

ACS800-17LC-1130-3 - - - -

ACS800-17LC-1680-3 - - - -

ACS800-17LC-2220-3 - - - -

ACS800-17LC-3300-3 - - - -

UN = 500 V

ACS800-17LC-0120-5 ACS800-607LC-0310-5 155 3×4.3 400/700

ACS800-17LC-0170-5 ACS800-607LC-0310-5 155 3×4.3 400/700

ACS800-17LC-0210-5 ACS800-607LC-0310-5 155 3×4.3 400/700

ACS800-17LC-0250-5 ACS800-607LC-0310-5 155 3×4.3 400/700

ACS800-17LC-0310-5 ACS800-607LC-0310-5 155 3×4.3 400/700

ACS800-17LC-0410-5 ACS800-607LC-0310-5 155 3×4.3 400/700

ACS800-17LC-0520-5 ACS800-607LC-0630-5 310 3×2.2 400/700

ACS800-17LC-0690-5 ACS800-607LC-0630-5 310 3×2.2 400/700

ACS800-17LC-1030-5 - - - -

ACS800-17LC-1350-5 - - - -

ACS800-17LC-2000-5 - - - -

ACS800-17LC-2640-5 - - - -

ACS800-17LC-3930-5 - - - -

UN = 690 V

ACS800-17LC-0130-7 ACS800-607LC-0430-7 155 3 × 6 400/700

ACS800-17LC-0170-7 ACS800-607LC-0430-7 155 3 × 6 400/700

ACS800-17LC-0210-7 ACS800-607LC-0430-7 155 3 × 6 400/700

ACS800-17LC-0280-7 ACS800-607LC-0430-7 155 3 × 6 400/700

ACS800-17LC-0390-7 ACS800-607LC-0430-7 155 3 × 6 400/700

ACS800-17LC-0470-7 ACS800-607LC-0430-7 155 3 × 6 400/700

ACS800-17LC-0630-7 ACS800-607LC-0870-7 310 3 × 3 400/700

ACS800-17LC-0950-7 - - - -

ACS800-17LC-1240-7 - - - -

ACS800-17LC-1840-7 - - - -

ACS800-17LC-2430-7 - - - -

ACS800-17LC-3620-7 - - - -

ACS800-17LC-4630-7 - - - -

ACS800-17LC-5300-7 - - - -

ACS800-17LC-5960-7 - - - -

Drive type Brake unit type IDC (rms) Resistor Cubicle width *

A Ohm mm

Technical data

150

Fuses

Notes:

• Larger fuses must not be used.• Fuses from other manufacturers can be used if they meet the ratings.• The recommended fuses are for branch circuit protection per NEC as required for

UL approval.

Main circuit AC fuses

Drive type Input current

AC fuse information (aR IEC and UL Recognized)

Qty Bussmann Ferraz Shawmut

UN = 400 V

ACS800-17LC-0110-3 144 3 170M4409 -

ACS800-17LC-0140-3 186 3 170M4411 PC31UD69V350TF

ACS800-17LC-0170-3 218 3 170M4411 PC31UD69V350TF

ACS800-17LC-0200-3 269 3 170M4413 PC31UD69V450TF

ACS800-17LC-0260-3 341 3 170M4415 PC31UD69V550TF

ACS800-17LC-0350-3 454 3 170M5413 PC32UD69V700TF

ACS800-17LC-0430-3 567 3 170M5415 PC32UD69V900TF

ACS800-17LC-0580-3 756 3 170M7059 PC33UD69V1250TF

ACS800-17LC-0870-3 1134 3 170M7059 PC33UD69V1250TF

ACS800-17LC-1130-3 1482 3 170M7062 PC44UD75V20CTQ

ACS800-17LC-1680-3 2200 3 170M7063 PC44UD70V25CTQ

ACS800-17LC-2220-3 2903 6 170M7062 PC44UD75V20CTQ

ACS800-17LC-3300-3 4309 6 170M7063 PC44UD70V25CTQ

UN = 500 V

ACS800-17LC-0120-5 126 3 170M4409 -

ACS800-17LC-0170-5 173 3 170M4411 PC31UD69V350TF

ACS800-17LC-0210-5 216 3 170M4411 PC31UD69V350TF

ACS800-17LC-0250-5 264 3 170M4413 PC31UD69V450TF

ACS800-17LC-0310-5 324 3 170M4415 PC31UD69V550TF

ACS800-17LC-0410-5 432 3 170M5413 PC32UD69V700TF

ACS800-17LC-0520-5 540 3 170M5415 PC32UD69V900TF

ACS800-17LC-0690-5 720 3 170M7059 PC33UD69V1250TF

ACS800-17LC-1030-5 1080 3 170M7059 PC33UD69V1250TF

ACS800-17LC-1350-5 1411 3 170M7062 PC44UD75V20CTQ

ACS800-17LC-2000-5 2095 3 170M7063 PC44UD70V25CTQ

ACS800-17LC-2640-5 2765 6 170M7062 PC44UD75V20CTQ

ACS800-17LC-3930-5 4104 6 170M7063 PC44UD70V25CTQ

UN = 690 V

ACS800-17LC-0130-7 96 3 170M4409 -

ACS800-17LC-0170-7 126 3 170M4409 -

ACS800-17LC-0210-7 162 3 170M4409 -

ACS800-17LC-0280-7 216 3 170M4411 PC31UD69V350TF

ACS800-17LC-0390-7 300 3 170M4413 PC31UD69V450TF

ACS800-17LC-0470-7 360 3 170M4415 PC31UD69V550TF

ACS800-17LC-0630-7 480 3 170M5413 PC32UD69V700TF

Technical data

151

Main circuit DC fuses

ACS800-17LC-0950-7 720 3 170M7059 PC33UD69V1250TF

ACS800-17LC-1240-7 941 3 170M7060 PC33UD69V1400TF

ACS800-17LC-1840-7 1397 3 170M7062 PC44UD75V20CTQ

ACS800-17LC-2430-7 1843 6 170M7060 PC33UD69V1400TF

ACS800-17LC-3620-7 2736 6 170M7062 PC44UD75V20CTQ

ACS800-17LC-4630-7 3648 12 170M7060 PC33UD69V1400TF

ACS800-17LC-5300-7 4104 9 170M7062 PC44UD75V20CTQ

ACS800-17LC-5960-7 4560 15 170M7060 PC33UD69V1400TF

Drive type Supply output (IEC and UL Recognized) Inverter input (IEC and UL Recognized)

Qty Bussmann Ferraz Shawmut Qty Bussmann Ferraz Shawmut

UN = 400 V

ACS800-17LC-0110-3 - - - - - -

ACS800-17LC-0140-3 - - - - - -

ACS800-17LC-0170-3 - - - - - -

ACS800-17LC-0200-3 - - - - - -

ACS800-17LC-0260-3 - - - - - -

ACS800-17LC-0350-3 - - - - - -

ACS800-17LC-0430-3 - - - - - -

ACS800-17LC-0580-3 - - - - - -

ACS800-17LC-0870-3 4 170M6415 PC33UD69V1100TF 4 170M6415 PC33UD69V1100TF





UN = 500 V

ACS800-17LC-0120-5 - - - - - -

ACS800-17LC-0170-5 - - - - - -

ACS800-17LC-0210-5 - - - - - -

ACS800-17LC-0250-5 - - - - - -

ACS800-17LC-0310-5 - - - - - -

ACS800-17LC-0410-5 - - - - - -

ACS800-17LC-0520-5 - - - - - -

ACS800-17LC-0690-5 - - - - - -






UN = 690 V

ACS800-17LC-0130-7 - - - - - -

ACS800-17LC-0170-7 - - - - - -

ACS800-17LC-0210-7 - - - - - -

Drive type Input current

AC fuse information (aR IEC and UL Recognized)

Qty Bussmann Ferraz Shawmut

Technical data

152

Dimensions, weights and free space requirements

The dimensions of the basic units are given below. See chapter Dimensions for the cubicle widths and heights of units with options. 400 mm free space is required at the top of the unit.

ACS800-17LC-0280-7 - - - - - -

ACS800-17LC-0390-7 - - - - - -

ACS800-17LC-0470-7 - - - - - -

ACS800-17LC-0630-7 - - - - - -

ACS800-17LC-0950-7 4 170M6546 PC73UD13C800TF 4 170M6546 PC73UD13C800TF

ACS800-17LC-1240-7 4 170M6549 PC73UD10C11CTF 4 170M6549 PC73UD10C11CTF







Drive type Height Width Depth Weight

mm mm mm kg

UN = 400 V

ACS800-17LC-0110-3 2003 1200 644 950

ACS800-17LC-0140-3 2003 1200 644 950

ACS800-17LC-0170-3 2003 1200 644 950

ACS800-17LC-0200-3 2003 1200 644 950

ACS800-17LC-0260-3 2003 1200 644 1100

ACS800-17LC-0350-3 2003 1200 644 1100

ACS800-17LC-0430-3 2003 1200 644 1100

ACS800-17LC-0580-3 2003 1200 644 1400

ACS800-17LC-0870-3 2003 1900 644 1950

ACS800-17LC-1130-3 2003 1900 644 1950

ACS800-17LC-1680-3 2003 3100 644 3000

ACS800-17LC-2220-3 2003 3200 644 3350

ACS800-17LC-3300-3 2003 5000 644 4950

UN = 500 V

ACS800-17LC-0120-5 2003 1200 644 950

ACS800-17LC-0170-5 2003 1200 644 950

ACS800-17LC-0210-5 2003 1200 644 950

ACS800-17LC-0250-5 2003 1200 644 950

ACS800-17LC-0310-5 2003 1200 644 1100

ACS800-17LC-0410-5 2003 1200 644 1100

ACS800-17LC-0520-5 2003 1200 644 1100

ACS800-17LC-0690-5 2003 1200 644 1400

ACS800-17LC-1030-5 2003 1900 644 1950

Drive type Supply output (IEC and UL Recognized) Inverter input (IEC and UL Recognized)

Qty Bussmann Ferraz Shawmut Qty Bussmann Ferraz Shawmut

Technical data

153

Losses, cooling data and noise

ACS800-17LC-1350-5 2003 1900 644 1950

ACS800-17LC-2000-5 2003 3100 644 3000

ACS800-17LC-2640-5 2003 3200 644 3350

ACS800-17LC-3930-5 2003 5000 644 4950

UN = 690 V

ACS800-17LC-0130-7 2003 1200 644 950

ACS800-17LC-0170-7 2003 1200 644 950

ACS800-17LC-0210-7 2003 1200 644 950

ACS800-17LC-0280-7 2003 1200 644 1100

ACS800-17LC-0390-7 2003 1200 644 1100

ACS800-17LC-0470-7 2003 1200 644 1100

ACS800-17LC-0630-7 2003 1200 644 1100

ACS800-17LC-0950-7 2003 1900 644 1950

ACS800-17LC-1240-7 2003 1900 644 1950

ACS800-17LC-1840-7 2003 2400 644 2350

ACS800-17LC-2430-7 2003 3200 644 3350

ACS800-17LC-3620-7 2003 4200 644 4250

ACS800-17LC-4630-7 2003 6200 644 6150

ACS800-17LC-5300-7 2003 6500 644 6000

ACS800-17LC-5960-7 2003 7400 644 7500

Drive type Losses Cooling data Noise

Ploss

(total)

Ploss

(coolant)

Ploss

(air)

Coolant quantity

Massflow Pressure loss

kW kW kW l l/min kPa dBA

UN = 400 V

ACS800-17LC-0110-3 5.1 5.0 0.1 10.3 41 100 59

ACS800-17LC-0140-3 7.1 7.0 0.1 10.3 41 100 59

ACS800-17LC-0170-3 6.7 6.6 0.1 10.3 41 100 59

ACS800-17LC-0200-3 7.7 7.5 0.1 10.3 41 100 59

ACS800-17LC-0260-3 12.4 12.2 0.2 10.3 41 100 59

ACS800-17LC-0350-3 14.6 14.3 0.3 10.3 41 100 59

ACS800-17LC-0430-3 17.4 17.1 0.3 10.3 41 100 59

ACS800-17LC-0580-3 22.1 21.7 0.4 11.1 41 100 59

ACS800-17LC-0870-3 33.3 32.6 0.7 16.6 79 100 62

ACS800-17LC-1130-3 43.2 42.3 0.9 16.6 79 100 62

ACS800-17LC-1680-3 64.4 63.1 1.3 26.1 116 100 64

ACS800-17LC-2220-3 84.5 82.8 1.7 29.9 152 100 65

ACS800-17LC-3300-3 125.3 122.8 2.5 44.6 226 100 67

UN = 500 V

ACS800-17LC-0120-5 4.8 4.7 0.1 10.3 41 100 59

ACS800-17LC-0170-5 6.5 6.4 0.1 10.3 41 100 59

Drive type Height Width Depth Weight

mm mm mm kg

Technical data

154

Internal cooling circuit data

See chapter Internal cooling circuit.

ACS800-17LC-0210-5 7.1 7.0 0.1 10.3 41 100 59

ACS800-17LC-0250-5 8.3 8.2 0.1 10.3 41 100 59

ACS800-17LC-0310-5 12.7 12.4 0.3 10.3 41 100 59

ACS800-17LC-0410-5 14.8 14.5 0.3 10.3 41 100 59

ACS800-17LC-0520-5 17.2 16.9 0.3 10.3 41 100 59

ACS800-17LC-0690-5 21.9 21.4 0.5 11.1 41 100 59

ACS800-17LC-1030-5 32.9 32.2 0.7 16.6 79 100 62

ACS800-17LC-1350-5 42.9 42.0 0.9 16.6 79 100 62

ACS800-17LC-2000-5 64.1 62.8 1.3 26.1 116 100 64

ACS800-17LC-2640-5 84.0 82.0 2.0 29.9 152 100 65

ACS800-17LC-3930-5 124.6 122.1 2.5 44.6 226 100 67

UN = 690 V

ACS800-17LC-0130-7 5.1 5.0 0.1 10.3 41 100 59

ACS800-17LC-0170-7 7.5 7.4 0.1 10.3 41 100 59

ACS800-17LC-0210-7 7.5 7.4 0.1 10.3 41 100 59

ACS800-17LC-0280-7 12.4 12.1 0.3 10.3 41 100 59

ACS800-17LC-0390-7 15.1 14.8 0.3 10.3 41 100 59

ACS800-17LC-0470-7 19.2 18.8 0.4 10.3 41 100 59

ACS800-17LC-0630-7 21.5 21.0 0.5 10.3 41 100 59

ACS800-17LC-0950-7 35.5 34.8 0.7 16.6 70 100 62

ACS800-17LC-1240-7 40.3 39.5 0.8 16.6 79 100 62

ACS800-17LC-1840-7 57.3 56.2 1.1 22.4 116 100 64

ACS800-17LC-2430-7 79.5 77.9 1.6 29.9 152 100 65

ACS800-17LC-3620-7 112.2 110.0 2.2 41.7 226 100 67

ACS800-17LC-4630-7 149.0 146.5 2.5 56.7 291 100 68

ACS800-17LC-5300-7 160.3 157.1 3.2 61.3 329 100 69

ACS800-17LC-5960-7 187.7 184.0 3.7 69.6 364 100 69

Drive type Losses Cooling data Noise

Ploss

(total)

Ploss

(coolant)

Ploss

(air)

Coolant quantity

Massflow Pressure loss

kW kW kW l l/min kPa dBA

Technical data

155

Terminal and lead-through data for the input power cable

The data is divided into subsections according to the number and size of the supply modules used. For the usage of modules in each drive type, see the section Type equivalence table on page 147. The cables enter the breaker cubicle.

Supply modules

Screw size Tightening torque Cable lead-throughs

1×R7i1×R8i

M12 (½”) 70 N·m (50 lbf·ft) 6 × Ø60 mm

2×R8i3×R8i4×R8i

M12 (½”) 70 N·m (50 lbf·ft) 18 × Ø60 mm

6×R8i…10×R8i

M12 (½”) 70 N·m (50 lbf·ft) 27 × Ø60 mm

Dimensions of input terminal in 600 mm breaker cubicle

Dimensions of input busbar in 1000 mm breaker cubicle

Dimensions of input terminal in R7i +R7i and R8i+R8i units

50 (2.0”)

45

(1

.8”)

Ø14

Technical data

156

Terminal and lead-through data for the motor cable

Units without common motor terminal cubicle (no option +H359)

When the drive is not equipped with common motor terminal cubicle, the motor cables enter the inverter module cubicle(s).

Inverter unit configuration

No. of busbars Screw sizeTightening

torqueCable lead-throughs

R7i, n×R8i n×3 M12 (½”) 70 N·m (52 lbf·ft)n × [6 × Ø60 mm

(2.36“)]

Dimensions of output busbar in inverter module cubicle

n = number of inverter modules

Technical data

157

Units with the Common Motor Terminal (CMT) cubicle (option +H359)

Terminal and lead-through data for the resistor cable

See ACS800-607LC 3-phase Brake Units Hardware Manual (3AFE68835861 [English]) or ACW 621 Braking Chopper Sections User’s Manual (3BFE64314874 [English]).

Terminal and lead-through data for the control cables

See section Default I/O connection diagram on page 103. Each incoming and inverter module cubicle is equipped with one EMI conductive cushions lead-through.

Inverter unit No. of busbars

Screw size Tightening torque Cable lead-throughsModules ACS800-17LC type

R7i, R8i, 2×R8i All 3 M12 (½”) 70 N·m (52 lbf·ft) 9 × Ø60 mm (2.36“) or 12 × Ø60 mm (in 400 mm

wide cubicles)3×R8i All 3 M12 (½”) 70 N·m (52 lbf·ft)

4×R8i, 5×R8i 690 V 3 M12 (½”) 70 N·m (52 lbf·ft) 12 × Ø60 mm

4×R8i 400 and 500 V 2×3 M12 (½”) 70 N·m (52 lbf·ft) 18 × Ø60 mm

5×R8i, 6×R8i 400 and 500 V 2×3 M12 (½”) 70 N·m (52 lbf·ft) 2 × (12 × Ø60 mm)

6×R8i, 7×R8i 690 V 2×3 M12 (½”) 70 N·m (52 lbf·ft) 18 × Ø60 mm

8×R8i, 9×R8i 690 V 2×3 M12 (½”) 70 N·m (52 lbf·ft) 2 × (12 × Ø60 mm)

10×R8i 690 V 3+(2×3) M12 (½”) 70 N·m (52 lbf·ft)12 × Ø60 mm + 18 × Ø60 mm

Dimensions of output busbar in 300 mm CMT cubicle



Technical data

158

Electrical power network specificationVoltage (U1) 380/400/415 V AC 3-phase ± 10% for 400 V AC units

380/400/415/440/460/480/500 V AC 3-phase ± 10% for 500 V AC units

525/550/575/600/660/690 V AC 3-phase ± 10% for 690 V AC units

Short-circuit withstand strength (IEC 60439-1)

Units without grounding switch: Maximum allowable prospective short-circuit current is 65 kA when protected by fuses given in the fuse tables.

Units with grounding switch: Maximum allowable prospective short-circuit current is 50 kA when protected by fuses given in the fuse tables.

Short-circuit current protection (UL 508A)

The drive is suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical amperes at 600 V maximum when protected by fuses given in the fuse tables.

Short-circuit current protection (CSA C22.2 No. 14-05)

The drive is suitable for use on a circuit capable of delivering not more than 65 kA rms symmetrical amperes at 600 V maximum when protected by fuses given in the fuse tables.

Frequency 50 ± 2 Hz or 60 ± 2 Hz. Maximum rate of change 17 %/s

Imbalance Max. ± 3% of nominal phase-to-phase input voltage

Voltage dips Max. 25%

Power factor

Harmonic distortion Harmonics are below the limits defined in IEEE519 for all Isc/IL. Each individual harmonic current fulfils IEEE519 table 10-3 for Isc/IL > 20. Current THD and each individual current harmonic fulfil IEC 61000-3-4 table 5.2 for Rsce > 66. The values will be met if the supply network voltage is not distorted by other loads and when the drive operates at the nominal load.

Motor connection dataMotor/Generator types Asynchronous AC induction and permanent magnet synchronous motors and generators

Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point

Frequency DTC mode: 0 to 3.2 · ff. Maximum frequency 300 Hz.

ff =

ff: frequency at field weakening point; UN: electrical power system voltage; Um: rated motor voltage; fm: rated motor frequency

Frequency resolution 0.01 Hz

Current See section Ratings.

Power limit 2 × Phd. After approximately 2 minutes at 2 × Phd, the limit is set at Pcont.max.

Field weakening point 8 to 300 Hz

Switching frequency 2…3 kHz (average)

Brake resistor connection dataSee section 3-phase brake units (option +D152), page 148, or section 1-phase brake choppers (option +D150) and resistors (option +D151), page 148.

cosphi = 1.00 (fundamental at nominal load)

I1 = fundamental input current rms valueI1Irms--------- cosphi⋅ 0.98>

Irms = total input current rms value

UN

Um· fm

Technical data

159

Control unit (RDCU/RMIO) connection dataAnalog inputs

With Standard Control Program two programmable differential current inputs (0 mA / 4 mA ... 20 mA, Rin = 100 ohm) and one programmable differential voltage input (-10 V / 0 V / 2 V ... +10 V, Rin = 200 kohm).

The analog inputs are galvanically isolated as a group.

Insulation test voltage 500 V AC, 1 min

Max. common mode voltage between the channels

±15 V DC

Common mode rejection ratio > 60 dB at 50 Hz

Resolution 0.025% (12 bit) for the -10 V ... +10 V input. 0.5% (11 bit) for the 0 ... +10 V and 0 ... 20 mA inputs.

Inaccuracy ±0.5% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ±100 ppm/°C (±56 ppm/°F), max.

Constant voltage outputVoltage +10 V DC, 0, -10 V DC ± 0.5% (Full Scale Range) at 25 °C (77 °F). Temperature

coefficient: ±100 ppm/°C (±56 ppm/°F) max.

Maximum load 10 mA

Applicable potentiometer 1 kohm to 10 kohm

Auxiliary power outputVoltage 24 V DC ± 10%, short circuit proof

Maximum current 250 mA (shared between this output and optional modules installed on the RMIO)

Analog outputsTwo programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm

Resolution 0.1% (10 bit)

Inaccuracy ±1% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ±200 ppm/°C (±111 ppm/°F) max.

Digital inputsWith Standard Control Program six programmable digital inputs (common ground: 24 V DC, -15% to +20%) and a start interlock input. Group isolated, can be divided in two isolated groups (see Isolation and grounding diagram below).

Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0” (high temperature), open circuit “0” (high temperature).

Internal supply for digital inputs (+24 V DC): short-circuit proof. An external 24 V DC supply can be used instead of the internal supply.

Insulation test voltage 500 V AC, 1 min

Logical thresholds < 8 V DC “0”, > 12 V DC “1”

Input current DI1 to DI 5: 10 mA, DI6: 5 mA

Filtering time constant 1 ms

Technical data

160

Relay outputsThree programmable relay outputs

Switching capacity 8 A at 24 V DC or 250 V AC, 0.4 A at 120 V DC

Minimum continuous current 5 mA rms at 24 V DC

Maximum continuous current 2 A rms

Insulation test voltage 4 kV AC, 1 minute

DDCS fibre optic linkWith optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System)

24 V DC power inputVoltage 24 V DC ± 10%

Typical current consumption (without optional modules)

250 mA

Maximum current consumption 1200 mA (with optional modules inserted)

The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also fulfil the requirements and the installation site is below 2000 m (6562 ft). Above 2000 m (6562 ft), see page 90.

Technical data

161

Isolation and grounding diagram

X20

1 VREF-

2 AGND

X21

1 VREF+

2 AGND

3 AI1+

4 AI1-

5 AI2+

6 AI2-

7 AI3+

8 AI3-

9 AO1+

10 AO1-

11 AO2+

12 AO2-

X22

1 DI1

2 DI2

3 DI3

4 DI4

9 DGND1

5 DI5

6 DI6

7 +24VD

8 +24VD

11 DIIL

10 DGND2

X23

1 +24 V

2 GND

X25

1 RO1

2 RO1

3 RO1

X26

1 RO2

2 RO2

3 RO2

X27

1 RO3

2 RO3

3 RO3

Common mode voltage between channels ±15 V

J1

(Test voltage: 500 V AC)

or

Jumper J1 settings:

All digital inputs share a common ground. This is the default setting.

Grounds of input groups DI1…DI4 and DI5/DI6/DIIL are separate (insulation voltage 50 V).

Ground

(Test voltage: 4 kV AC)

Technical data

162

Efficiency> 97% (at rated current and nominal supply voltage)

Degree of protectionIP42 (UL Type 1), IP54, (UL Type 12)

Ambient conditionsEnvironmental limits for the drive are given below. The drive must be used in a heated, indoor controlled environment.

Operation installed for stationary use

Storagein the protective package

Transportationin the protective package

Installation site altitude 0 to 4000 m (13123 ft) above sea level. 690 V units: 0 to 2000 m (6562 ft) above sea level. Above 1000 m (3281 ft), see Derating on page 146.

- -

Air temperature 0…+55° (+32…+131°F), no frost allowed[above +45°C (+113°F), see Derating on page 146]

-40…+70°C (-40 to +158°F) -40…+70°C (-40 to +158°F)

Relative humidity 5 to 95% Max. 95% Max. 95%

No condensation allowed. Maximum allowed relative humidity is 60% in the presence of corrosive gases.

Contamination levels (IEC60721-3-3, IEC60721-3-2, IEC60721-3-1)

No conductive dust allowed.

Boards with coating: Chemical gases: Class 3C2Solid particles: Class 3S2



Atmospheric pressure 70 to 106 kPa0.7 to 1.05 atmospheres

70 to 106 kPa0.7 to 1.05 atmospheres

60 to 106 kPa0.6 to 1.05 atmospheres

Vibration Marine requirements±1 mm (peak value, 2…13.2 Hz)0.7g (13.2 - 100 Hz)Max. amplification 10

IEC 60068-2-60,075 mm (0…58 Hz) 10 m/s2 (58…150Hz) Max. amplification 10

1M2, IEC 60721-3-11.5 mm (2…9 Hz)5 m/s2 (9…200 Hz)

2M2, IEC 60721-3-23,5 mm (2…9 Hz)10 m/s2 (9…200 Hz) Random 10-200 Hz, acceleration spectral density 1 m2/s³

Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), 11 ms

Max. 100 m/s2 (330 ft./s2), 11 ms

Free fall Not allowed 100 mm (4 in.) for weight over 100 kg (220 lb.)

100 mm (4 in.) for weight over 100 kg (220 lb.)

MaterialsCabinet Hot-dip zinc-coated (thickness approx. 20 µm) steel sheet (thickness 1.5 mm) with

polyester thermosetting powder coating (thickness approx. 80 µm) on visible surfaces except back panel. Colour: RAL 7035 (light beige, semigloss).

Busbars Tin- or silver-plated copper

Technical data

163

Internal cooling circuit piping Aluminium, acid-fast stainless steel, PA pipes (inner/outer diameter in drain and bleed pipes: 9 mm / 11.5 mm; inner/outer diameter in main pipes of the modules: 13.5 mm / 17.5 mm)

Fire safety of materials (IEC 60332-1)

Insulating materials and non-metallic items: Mostly self-extinctive

Packaging Frame: Wood or plywood. Plastic wrapping: PE-LD. Bands: PP or steel.

Disposal The drive contains raw materials that should be recycled to preserve energy and natural resources. The package materials are environmentally compatible and recyclable. All metal parts can be recycled. The plastic parts can either be recycled or burned under controlled circumstances, according to local regulations. Most recyclable parts are marked with recycling marks.If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the printed circuit boards contain lead, both of which are classified as hazardous waste within the EU. They must be removed and handled according to local regulations. For further information on environmental aspects and more detailed recycling instructions, please contact your local ABB distributor.

Technical data

164

Auxiliary circuit current consumption

The table below shows the current consumption of the main components in the auxiliary circuit. See also section Connecting external power supply for the auxiliary circuits on page 100 for instructions.

1) values for each single unit

2) total value for multiple units

3) air-cooled IP54 sine filter

Drive/Load Current consumption (A)

Externally supplied fan circuits Externally supplied control circuits

Externally supplied fan and control circuits

230 V AC 230 V AC 115 V AC 230 V AC 115 V AC 230 V AC 230 V AC 115 V AC

50 Hz 60 Hz 60 Hz 50/60 Hz 60 Hz 50 Hz 60 Hz 60 Hz

Drives

1×R7i + 1×R7i 1×R8i + 1×R8i

n.a. n.a. n.a. 1.1 2.2 n.a. n.a. n.a.

2×R8i + 2×R8i 5.1 5.8 11.6 2.2 4.4 7.3 8 16

2×R8i + 2×R8i 5.1 5.8 11.6 2.2 4.4 7.3 8 16

3×R8i + 3×R8i 7.3 8.3 17 2.2 4.4 9.5 10.5 21.4

4×R8i + 4×R8i 9.5 11 22 2.2 4.4 11.7 13.2 26.4

6×R8i + 6×R8i 14.5 16.5 32.5 2.5 5 17 19 37.5

8×R8i + 7×R8i 18 21 41 2.5 5 20.5 23.5 46

9×R8i + 8×R8i 21 23 46 2.5 5 23.5 25.5 51

10×R8i + 9×R8i 23 26 52 2.5 5 25.5 28.5 57

Brake units

3-phase brake units (ACS800-607LC)

1.4 1.5 3 1) - - - - -

NBRW fan unit 0.3 0.3 0.5 1) - - - - -

Brake resistors (2 × SAFUR)

2.8 3.4 6.8 1) - - - - -

Control circuit

Single 3-phase brake unit

- - - 0.1 0.2 - - -

Multiple 3-phase brake units

- - - 0.5 1 2) - - -

Sine filters

NSIN0210-0485/6 0.35 0.4 0.8 1) - - - - -

NSIN0210-0485/6 0.7 0.8 1.6 1) 3) - - - - -

NSIN0900-1380/6 2.8 3.4 6.8 1) - - - - -

NSIN0900-1380/6 4.8 5.5 11 1) 3) - - - - -

Optional cabinets

Top exit (+H351+H359))

0.35 0.4 0.8 - - - - -

Cooling unit (+C139, +C140, +C141): 24 V DC power supply and control relays

See ACS800-1007LC User’s Manual (3AFE68621101 [English]).

Technical data

165

Applicable standardsThe drive complies with the following standards.

• EN ISO 13849-1:2008 Safety of machinery – Safety-related parts of control systems – Part 1: General principles for design

• EN 60204-1:2006 Safety of machinery. Electrical equipment of machines. Part 1: General requirements.

• IEC/EN 60529:1991 + corrigendum May 1993 + amendment A1:2000)

Degrees of protection provided by enclosures (IP code).

• IEC 60664-1:2007 Insulation coordination for equipment within low-voltage systems. Part 1: Principles, requirements and tests

• EN 61800-3:2004 Adjustable speed electrical power drive systems - Part 3: EMC product standard including specific test methods

• EN 61800-5-1:2007 Adjustable speed electrical power drive systems - Part 5-1: Safety requirements – Electrical, thermal and energy

• EN 61800-5-2:2007 Adjustable speed electrical power drive systems - Part 5-2: Safety requirements – Functional

• UL 508A: 1st Edition UL Standard for Safety, Power Conversion Equipment, second edition

• CSA C22.2 No. 14-05 Industrial control equipment

Technical data

166

CE marking

A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low Voltage, and EMC Directives. The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component.

Compliance with the European Low Voltage Directive

The compliance with the European Low Voltage Directive has been verified according to standards EN 60204-1 and EN 61800-5-1.

Compliance with the European EMC Directive

The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union. The EMC product standard (EN 61800-3:2004) covers requirements stated for drives. See section Compliance with EN 61800-3:2004 below.

Compliance with the European Machinery Directive

The drive is an electronic product which is covered by the European Low Voltage Directive. However, the drive can be equipped with the Safe torque off function and other safety functions for machinery which, as safety components, are in the scope of the Machinery Directive. These functions of the drive comply with European harmonized standards such as EN 61800-5-2. The declaration of conformity for each function is in the appropriate function-specific manual.

Compliance with EN 61800-3:2004

Definitions

EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality.

First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes.

Second environment includes establishments connected to a network not supplying domestic premises.

Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and commissioned only by a professional when used in the first environment. Note: A professional is a person or organisation having necessary skills in installing and/or commissioning power drive systems, including their EMC aspects.

Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment.

Technical data

167

Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above 400 A, or intended for use in complex systems in the second environment.

Category C2

The 400 and 500 V drives comply with the standard with the following provisions:

1. The supply unit is equipped with EMC filter +E202.

2. The motor and control cables are selected as specified in chapter Planning the electrical installation.

3. The drive is installed according to the instructions given in chapter Electrical installation.

4. Motor cables do not exceed 100 metres (328 ft).

WARNING! The drive may cause radio interference if used in a residential or domestic environment. The user is required to take measures to prevent interference, in addition to the requirements for CE compliance listed above, if necessary.

Note: It is not allowed to install a drive equipped with EMC filter +E202 on IT (unearthed) systems. The supply network becomes connected to earth potential through the EMC filter capacitors which may cause danger or damage the unit.

Category C3

The drive complies with the standard with the following provisions:



3. Motor cables do not exceed 100 metres (328 ft).

WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.

Technical data

168

Category C4

If the provisions under Category C3 cannot be met, the requirements of the standard can be met as follows:

1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply transformer with static screening between the primary and secondary windings can be used.

2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative.



WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.

Low voltage

Equipment

Low voltage

Equipment

Equipment(victim)

Supply transformer

Medium voltage network

Static screen

Point of measurement

Drive

Neighbouring network

Technical data

169

UL marking

The drive is cULus listed and cCSAus certified. The approvals are valid with rated voltages up to 600 V. The markings are attached to the drives when options +C129 (cULus) or +C134 (cCSAus) are selected.

UL checklist

Input power connection – Short-circuit current protection (UL 508A): The drive is suitable for use in a circuit capable of delivering not more than 100,000 symmetrical amperes (rms) at 600 V maximum when protected with the fuses given in section Fuses, page 150.

Disconnecting device (disconnecting means) – See chapter Planning the electrical installation, page 69.

Ambient conditions – The drive is to be used in a heated indoor controlled environment. For the specifications, see Ambient conditions on page 162.

Input cable fuses – For installation in the United States, branch circuit protection must be provided in accordance with National Electrical Code (NEC) and any applicable local codes. To fulfil this requirement, use the US fuses given in section Fuses, page 150.

For installation in Canada, branch circuit protection must be provided in accordance with Canadian Electrical Code and any applicable provincial codes. To fulfil this requirement, use the UL classified fuses given in section Fuses, page 150.

Power cable selection – See chapter Planning the electrical installation, page 69.

Power cable connections – For the connection diagram and tightening torques, see Electrical installation.

Control connections – For the connection diagram and tightening torques, see Electrical installation.

Overload protection – The drive provides overload protection in accordance with the National Electrical Code (US). See the Firmware Manual for setting. Default setting is off, must be activated at start-up.

Brake unit – The drive can be equipped with a brake unit that will allow the drive to dissipate regenerative energy (normally associated with quickly decelerating a motor).

UL standards – See Applicable standards on page 165.

CSA marking

The ACS800-17LC is CSA marked.

Approvals

The ACS800-17LC+C121 units are type approved by American Bureau of Shipping, Det Norske Veritas and Lloyd’s Register of Shipping.

Technical data

170

Cyber security disclaimer

This product is designed to be connected to and to communicate information and data via a network interface. It is Customer's sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network (as the case may be). Customer shall establish and maintain any appropriate measures (such as but not limited to the installation of firewalls, application of authentication measures, encryption of data, installation of anti-virus programs, etc) to protect the product, the network, its system and the interface against any kind of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or information. ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

Disclaimer

The manufacturer shall have no obligation with respect to any product which (i) has been improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident; (iii) has been used in a manner contrary to the manufacturer's instructions; or (iv) has failed as a result of ordinary wear and tear.

Technical data

171

Dimensions


This chapter contains example dimension drawings and a table of dimensions.

Table of dimensions

Drive type Height 1 Height 2 Width 1

(basic)

Width 2

(+H353)

Width 3

(+H359)

mm mm mm mm mm

UN = 400 V

ACS800-17LC-0110-3 2003 2315 1200 1500 300

ACS800-17LC-0140-3 2003 2315 1200 1500 300

ACS800-17LC-0170-3 2003 2315 1200 1500 300

ACS800-17LC-0200-3 2003 2315 1200 1500 300

ACS800-17LC-0260-3 2003 2315 1200 1500 300

ACS800-17LC-0350-3 2003 2315 1200 1500 300

ACS800-17LC-0430-3 2003 2315 1200 1500 300

ACS800-17LC-0580-3 2003 2315 1200 1500 300

ACS800-17LC-0870-3 2003 2315 1900 2300 300

ACS800-17LC-1130-3 2003 2315 1900 2300 300

ACS800-17LC-1680-3 2003 2315 3100 3700 400

ACS800-17LC-2220-3 2003 2315 3200 4000 600

ACS800-17LC-3300-3 2003 2315 5000 6000 400 + 400

UN = 500 V

ACS800-17LC-0120-5 2003 2315 1200 1500 300

ACS800-17LC-0170-5 2003 2315 1200 1500 300

ACS800-17LC-0210-5 2003 2315 1200 1500 300

ACS800-17LC-0250-5 2003 2315 1200 1500 300

ACS800-17LC-0310-5 2003 2315 1200 1500 300

ACS800-17LC-0410-5 2003 2315 1200 1500 300

ACS800-17LC-0520-5 2003 2315 1200 1500 300

ACS800-17LC-0690-5 2003 2315 1200 1500 300

ACS800-17LC-1030-5 2003 2315 1900 2300 300

ACS800-17LC-1350-5 2003 2315 1900 2300 300

ACS800-17LC-2000-5 2003 2315 3100 3700 400

ACS800-17LC-2640-5 2003 2315 3200 4000 600

ACS800-17LC-3930-5 2003 2315 5000 6000 400 + 400

UN = 690 V

ACS800-17LC-0130-7 2003 2315 1200 1500 300

ACS800-17LC-0170-7 2003 2315 1200 1500 300

ACS800-17LC-0210-7 2003 2315 1200 1500 300

ACS800-17LC-0280-7 2003 2315 1200 1500 300

Dimensions

172

ACS800-17LC-0390-7 2003 2315 1200 1500 300

ACS800-17LC-0470-7 2003 2315 1200 1500 300

ACS800-17LC-0630-7 2003 2315 1200 1500 300

ACS800-17LC-0950-7 2003 2315 1900 2200 300

ACS800-17LC-1240-7 2003 2315 1900 2200 300

ACS800-17LC-1840-7 2003 2315 2400 2800 300

ACS800-17LC-2430-7 2003 2315 3200 3800 400

ACS800-17LC-3620-7 2003 2315 4200 5000 600

ACS800-17LC-4630-7 2003 2315 6200 7000 400 + 400

ACS800-17LC-5300-7 2003 2315 6500 7500 400 + 400

ACS800-17LC-5960-7 2003 2315 7400 8400 400 + 400

Height 1: Height of the basic bottom entry/exit unit

Height 2: Height with optional sine output filter (+E206)

Width 1: Width of the basic unit

Width 2: Width with optional top exit of cables (+H353)

Width 3: Width of commen motor terminal cubicle (option +H359) for units with bottom exit of cables

Optional auxiliary control cubicle width: 400 mm or 600 mm

1-phase brake chopper (option +D150) cubicle width: 400 mm

3-phase brake chopper (option +D152) cubicle width: 400 mm (bottom exit) and 700 mm (top exit)

Brake resistor cubicle width (option +D151): 800 mm for each 2×SAFUR resistor package

Drive type Height 1 Height 2 Width 1

(basic)

Width 2

(+H353)

Width 3

(+H359)

mm mm mm mm mm

Dimensions

173

Frame sizes R7i+R7i and R8i+R8i (bottom entry/exit)

Dimensions

174

Frame sizes R7i+R7i and R8i+R8i (marine units, +C121)

Dimensions

Further information

Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.

Product training

For information on ABB product training, navigate to new.abb.com/service/training.

Providing feedback on ABB manuals

Your comments on our manuals are welcome. Navigate to new.abb.com/drives/manuals-feedback-form.

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet at www.abb.com/drives/documents.

http://www.abb.com/drives/documents

http://www.abb.com/searchchannels

http://new.abb.com/drives/manuals-feedback-form

http://new.abb.com/service/training

www.abb.com/driveswww.abb.com/drivespartners

Contact us

3AUA0000065339 Rev B (EN) 2016-06-07

Documents

ACS800-17LC Hardware Manual